Operator’s Manual

™
TANDEM CRUISER
For use with machines having Code Numbers:
11824, 12332

Register your machine:

www.lincolnelectric.com/register
Authorized Service and Distributor Locator:
www.lincolnelectric.com/locator

Save for future reference

Date Purchased

Code: (ex: 10859)

Serial: (ex: U1060512345)

IM10114-A | Issue Date Sept- 14

© Lincoln Global, Inc. All Rights Reserved.
 THANK YOU FOR SELECTING
A QUALITY PRODUCT BY KEEP YOUR HEAD OUT OF THE FUMES.
LINCOLN ELECTRIC. 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
PLEASE EXAMINE CARTON AND EQUIPMENT FOR Sheet (SDS) and the warning label
DAMAGE IMMEDIATELY that appears on all containers of
When this equipment is shipped, title passes to the purchaser welding materials.
upon receipt by the carrier. Consequently, claims for material USE ENOUGH VENTILATION or
damaged in shipment must be made by the purchaser against the exhaust at the arc, or both, to
transportation company at the time the shipment is received. 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).
SAFETY DEPENDS ON YOU
USE NATURAL DRAFTS or fans to keep the fumes away
Lincoln arc welding and cutting equipment is designed and built
from your face.
with safety in mind. However, your overall safety can be increased
by proper installation ... and thoughtful operation on your part. If you develop unusual symptoms, see your supervisor.
DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT Perhaps the welding atmosphere and ventilation system
WITHOUT READING THIS MANUAL AND THE SAFETY should be checked.
PRECAUTIONS CONTAINED THROUGHOUT. And, most importantly,
think before you act and be careful.
WEAR CORRECT EYE, EAR &
BODY PROTECTION
WARNING PROTECT your eyes and face with welding helmet
properly fitted and with proper grade of filter plate
(See ANSI Z49.1).
This statement appears where the information must be followed
exactly to avoid serious personal injury or loss of life. PROTECT your body from welding spatter and arc
flash with protective clothing including woolen
clothing, flame-proof apron and gloves, leather
CAUTION leggings, and high boots.
PROTECT others from splatter, flash, and glare
This statement appears where the information must be followed with protective screens or barriers.
to avoid minor personal injury or damage to this equipment.
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.
Safety 01 of 04 - 5/16/2018
 SAFETY

SECTION A: 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

WARNINGS
fumes have been eliminated.
1.d. Keep all equipment safety guards, covers
and devices in position and in good repair.
CALIFORNIA PROPOSITION 65 WARNINGS Keep hands, hair, clothing and tools away
from V-belts, gears, fans and all other
moving parts when starting, operating or
WARNING: Breathing diesel engine exhaust repairing equipment.
exposes you to chemicals known to the State 1.e. In some cases it may be necessary to remove safety guards to
of California to cause cancer and birth defects, perform required maintenance. Remove guards only when
or other reproductive harm. necessary and replace them when the maintenance requiring
• Always start and operate the engine in a their removal is complete. Always use the greatest care when
well-ventilated area. working near moving parts.
• If in an exposed area, vent the exhaust to the outside. 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
• Do not modify or tamper with the exhaust system.
rods while the engine is running.
• Do not idle the engine except as necessary.
1.g. To prevent accidentally starting gasoline engines while turning
For more information go to the engine or welding generator during maintenance work,
www.P65 warnings.ca.gov/diesel disconnect the spark plug wires, distributor cap or magneto wire
as appropriate.
WARNING: This product, when used for welding or 1.h. To avoid scalding, do not remove the radiator
cutting, produces fumes or gases which contain pressure cap when the engine is hot.
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 ELECTRIC AND

www.P65warnings.ca.gov MAGNETIC FIELDS MAY
BE DANGEROUS
ARC WELDING CAN BE HAZARDOUS. PROTECT
YOURSELF AND OTHERS FROM POSSIBLE SERIOUS 2.a. Electric current flowing through any conductor
INJURY OR DEATH. KEEP CHILDREN AWAY. causes localized Electric and Magnetic Fields (EMF).
PACEMAKER WEARERS SHOULD CONSULT WITH Welding current creates EMF fields around welding cables
THEIR DOCTOR BEFORE OPERATING. and welding machines
Read and understand the following safety highlights. For 2.b. EMF fields may interfere with some pacemakers, and
additional safety information, it is strongly recommended welders having a pacemaker should consult their physician
that you purchase a copy of “Safety in Welding & Cutting - before welding.
ANSI Standard Z49.1” from the American Welding Society,
2.c. Exposure to EMF fields in welding may have other health effects
P.O. Box 351040, Miami, Florida 33135 or CSA Standard
which are now not known.
W117.2-1974. A Free copy of “Arc Welding Safety” booklet
E205 is available from the Lincoln Electric Company, 2.d. All welders should use the following procedures in order to
22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. minimize exposure to EMF fields from the welding circuit:
BE SURE THAT ALL INSTALLATION, OPERATION, 2.d.1. Route the electrode and work cables together - Secure
MAINTENANCE AND REPAIR PROCEDURES ARE them with tape when possible.
PERFORMED ONLY BY QUALIFIED INDIVIDUALS. 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
FOR ENGINE POWERED work cable should also be on your right side.

EQUIPMENT. 2.d.4. Connect the work cable to the workpiece as close as pos-
sible to the area being welded.
1.a. Turn the engine off before troubleshooting 2.d.5. Do not work next to welding power source.
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 Safety 02 of 04 - 5/16/2018
 SAFETY

ELECTRIC SHOCK ARC RAYS CAN BURN.

CAN KILL.
3.a. The electrode and work (or ground) circuits are 4.a. Use a shield with the proper filter and cover plates to protect your
electrically “hot” when the welder is on. Do eyes from sparks and the rays of the arc when welding or
not touch these “hot” parts with your bare skin or wet clothing. observing open arc welding. Headshield and filter lens should
Wear dry, hole-free gloves to insulate hands. conform to ANSI Z87. I standards.
3.b. Insulate yourself from work and ground using dry insulation. 4.b. Use suitable clothing made from durable flame-resistant material
Make certain the insulation is large enough to cover your full area to protect your skin and that of your helpers from the arc rays.
of physical contact with work and ground.
4.c. Protect other nearby personnel with suitable, non-flammable
In addition to the normal safety precautions, if screening and/or warn them not to watch the arc nor expose
welding must be performed under electrically themselves to the arc rays or to hot spatter or metal.
hazardous conditions (in damp locations or while
wearing wet clothing; on metal structures such as
floors, gratings or scaffolds; when in cramped FUMES AND GASES
positions such as sitting, kneeling or lying, if there CAN BE DANGEROUS.
is a high risk of unavoidable or accidental contact
with the workpiece or ground) use the following 5.a. Welding may produce fumes and gases
equipment: hazardous to health. Avoid breathing these
• Semiautomatic DC Constant Voltage (Wire) Welder. fumes and gases. When welding, keep your head out of the fume.
• DC Manual (Stick) Welder. Use enough ventilation and/or exhaust at the arc to keep fumes
and gases away from the breathing zone. When welding
• AC Welder with Reduced Voltage Control.
hardfacing (see instructions on container or SDS)
3.c. In semiautomatic or automatic wire welding, the electrode, or on lead or cadmium plated steel and other
electrode reel, welding head, nozzle or semiautomatic welding metals or coatings which produce highly toxic
gun are also electrically “hot”. fumes, keep exposure as low as possible and
3.d. Always be sure the work cable makes a good electrical within applicable OSHA PEL and ACGIH TLV limits
connection with the metal being welded. The connection should using local exhaust or mechanical ventilation
be as close as possible to the area being welded. unless exposure assessments indicate otherwise.
In confined spaces or in some circumstances,
3.e. Ground the work or metal to be welded to a good electrical (earth) outdoors, a respirator may also be required.
ground. Additional precautions are also required when
3.f. Maintain the electrode holder, work clamp, welding cable and welding
welding machine in good, safe operating condition. Replace on galvanized steel.
damaged insulation. 5. b. The operation of welding fume control equipment is affected by
3.g. Never dip the electrode in water for cooling. various factors including proper use and positioning of the
equipment, maintenance of the equipment and the specific
3.h. Never simultaneously touch electrically “hot” parts of electrode welding procedure and application involved. Worker exposure
holders connected to two welders because voltage between the level should be checked upon installation and periodically
two can be the total of the open circuit voltage of both thereafter to be certain it is within applicable OSHA PEL and
welders. ACGIH TLV limits.
3.i. When working above floor level, use a safety belt to protect 5.c. Do not weld in locations near chlorinated hydrocarbon vapors
yourself from a fall should you get a shock. coming from degreasing, cleaning or spraying operations. The
heat and rays of the arc can react with solvent vapors to form
3.j. Also see Items 6.c. and 8.
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 03 of 04 - 5/16/2018
 SAFETY

WELDING AND CUTTING CYLINDER MAY EXPLODE IF

SPARKS CAN CAUSE DAMAGED.
FIRE OR EXPLOSION. 7.a. Use only compressed gas cylinders containing
6.a. Remove fire hazards from the welding area. If the correct shielding gas for the process used
this is not possible, cover them to prevent the welding sparks and properly operating regulators designed for
from starting a fire. Remember that welding sparks and hot the gas and pressure used. All hoses, fittings,
materials from welding can easily go through small cracks and etc. should be suitable for the application and
openings to adjacent areas. Avoid welding near hydraulic lines. maintained in good condition.
Have a fire extinguisher readily available. 7.b. Always keep cylinders in an upright position securely chained to
6.b. Where compressed gases are to be used at the job site, special an undercarriage or fixed support.
precautions should be used to prevent hazardous situations. 7.c. Cylinders should be located:
Refer to “Safety in Welding and Cutting” (ANSI Standard Z49.1)
• Away from areas where they may be struck or subjected
and the operating information for the equipment being used.
to physical damage.
6.c. When not welding, make certain no part of the electrode circuit is • A safe distance from arc welding or cutting operations
touching the work or ground. Accidental contact can cause and any other source of heat, sparks, or flame.
overheating and create a fire hazard.
7.d. Never allow the electrode, electrode holder or any other
6.d. Do not heat, cut or weld tanks, drums or containers until the
electrically “hot” parts to touch a cylinder.
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances inside. 7.e. Keep your head and face away from the cylinder valve outlet
They can cause an explosion even though they have been when opening the cylinder valve.
“cleaned”. For information, purchase “Recommended Safe 7.f. Valve protection caps should always be in place and hand tight
Practices for the Preparation for Welding and Cutting of except when the cylinder is in use or connected for use.
Containers and Piping That Have Held Hazardous Substances”,
AWS F4.1 from the American Welding Society 7.g. Read and follow the instructions on compressed gas cylinders,
(see address above). associated equipment, and CGA publication P-l, “Precautions for
Safe Handling of Compressed Gases in Cylinders,” available from
6.e. Vent hollow castings or containers before heating, cutting or the Compressed Gas Association, 14501 George Carter Way
welding. They may explode.
Chantilly, VA 20151.
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. FOR ELECTRICALLY
6.g. Connect the work cable to the work as close to the welding area POWERED EQUIPMENT.
as practical. Work cables connected to the building framework or
other locations away from the welding area increase the 8.a. Turn off input power using the disconnect
possibility of the welding current passing through lifting chains, switch at the fuse box before working on
crane cables or other alternate circuits. This can create fire the equipment.
hazards or overheat lifting chains or cables until they fail.
8.b. Install equipment in accordance with the U.S. National Electrical
6.h. Also see item 1.c. Code, all local codes and the manufacturer’s recommendations.
6.I. Read and follow NFPA 51B “Standard for Fire Prevention During 8.c. Ground the equipment in accordance with the U.S. National
Welding, Cutting and Other Hot Work”, available from NFPA, 1 Electrical Code and the manufacturer’s recommendations.
Batterymarch Park, PO box 9101, Quincy, MA 022690-9101.
6.j. Do not use a welding power source for pipe thawing.
Refer to
http://www.lincolnelectric.com/safety
for additional safety information.

Safety 04 of 04 - 5/16/2018
 TABLE OF CONTENTS
Page
Installation.......................................................................................................................Section A
Technical Specifications.......................................................................................................A-1
General Physical Description ...............................................................................................A-2
General Functional Description ............................................................................................A-2
Recommended Processes ...................................................................................................A-2
Process Limitations ..............................................................................................................A-2
Equipment Limitations ..........................................................................................................A-2
Recommended Power Sources, Design Features ...............................................................A-2
Parts Included with Tandem Cruiser ....................................................................................A-3
Location................................................................................................................................A-4
General Assembly, Removing the Butt Joint Guide .............................................................A-5
Outriggers.............................................................................................................................A-6
Butt Joint Guide, 2 Wheels ...........................................................................................A-7, A-8
Front Wheels ........................................................................................................................A-9
Leveling the Wheels ...........................................................................................................A-10
Cross Slide and Wire Drive ................................................................................................A-11
Wire Reel Spindle, Take Off Arm .......................................................................................A-12
Wire Wheel Enclosure and Spindle Parts.................................................................A-13, A-14
50-60LB. Coil Mounting......................................................................................................A-15
Wire Straightener Adjustment, Feedplate Rotation ............................................................A-16
Flux Hopper........................................................................................................................A-17
Cables ................................................................................................................................A-17
Cable Connections .............................................................................................................A-18
Weld Cable Sizes ...............................................................................................................A-19
System Set-Up ...................................................................................................................A-20
Butt Joints, Fillet Joints.......................................................................................................A-21
Flat Fillet ((Trough), 45º (Trough) .............................................................................A-22, A-27

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

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
TANDEM CRUISER TM INSTALLATION

TECHNICAL SPECIFICATIONS - TANDEM CRUISER™ K-3083-1

Wire Feeders - Input Voltage and Current
VOLTAGE INPUT AMPERES NOTES

40 VDC 8 AMPS Lead Arc

40 VDC 8 AMPS Trail Arc

Rated Output
DUTY CYCLE AMPERES

100% 1000 AMPS per arc

Physical Dimensions (as shipped from the factory)*
(Overall Size and Weight Dependent Upon Configuration)
MODEL HEIGHT WIDTH DEPTH WEIGHT

K3083-1 36.5 in. (901.7mm) 45.50 in (1,155.7mm) 41.5 in (1,054.1mm) 300 lb. (136 kg)
Temperature Ranges
Operating Temperature -40ºF to 122ºF (-40ºC to +50ºC)
Storage Temperature -40ºF to 185ºF (-40ºC to +85ºC)
SAW
GEARING WFS Range Wire Sizes

57:1 50 to 500 ipm 1/16 to 3/32 inch

(1.3 to 12.5 m/min) (1.6 to 2.4 mm)

95:1 15 to 300 ipm 1/16 to 3/32 inch

(0.4 to 7.5 m/min) (1.6 to 2.4 mm)

142:1* 15 to 200 ipm 1/16 to 7/32 inch

(0.4 to 5.0 m/min) (1.6 to 5.6 mm)

* = gearing installed in the wire drive as equipped from the factory.

IP23S

A-1
TANDEM CRUISER TM INSTALLATION

• There is no 115 VAC in the tractor.

• The minimum turning radius of the Tandem
GENERAL PHYSICAL DESCRIPTION
Cruiser™ is 10 feet when assembled with 3 wheels.
The Tandem Cruiser™ is a self propelled, modular
• The minimum turning radius of the Tandem
platform for performing submerged arc welds. A
Cruiser™ is 20 feet when assembled with 4 wheels.
unique tube and clamp design provides flexibility to
• The rubber wheels are rated to 500°F (260°C)
mount the feeding components in any position.
• The curved nozzle extensions may be used with up
to 3/16” wire.
Wire is fed to the arc with proven wire drives. All of the • For use with 50/60 lb coils.
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
RECOMMENDED POWER SOURCES
axes for setting torch drag/pull angle and torch tilt • Power Wave® AC/DC 1000
angle.
DESIGN FEATURES
The wire drive is mounted to two heavy duty X-Y
slides. The cross slides allow easy adjustment of the
Loaded with Standard Features

electrode stick-out and position of the wire.

Arc Performance
• The Tandem Cruiser™ and Power Wave® AC/DC
Driving the tractor is a permanent magnet dc motor 1000 combine for new levels of submerged arc pro-
with a 5 stage gear box built with all metal gears. A ductivity.
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 • Easy to read pendant displays information for the
User Controls

aluminum core. Also mounted on the axle are guide lead and trail arc.
wheels and gears for operating on K396 track sections. • 4 memories on the lead arc and 8 memories on the
trail arc for quick selection of common procedures.
The flexible wheel configuration lets the tractor be • Full sequence control for tailoring the weld from
assembled in a manner for the best balance while start to end.
aligning the wheels for the tracking of the joint. • All welding controls located at the pendant, includ-
ing program selection.
• Laser pointer to aid in steering the Cruiser.
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 • Changeable gears for feeding small diameter wires
Wire Drive
impacts and high temperatures. at high speed and large diameter wires at low
speed.
• High torque, permanent magnet DC motor with
tachometer for accurate wire feed speed control.
GENERAL FUNCTIONAL DESCRIPTION
The TANDEM CRUISER™ is a modular platform for
• Three roll wire straightener included.
submerged arc welding.
• Uses standard Lincoln submerged arc contact noz-
zles.
RECOMMENDED PROCESSES
• Tandem SAW (AC, DC+, DC-) up to 1000 amps per
• Permanent magnet DC motor with encoder for
Tractor and Frame
arc.
steady, accurate travel speeds.
• All steel gears for long life.
• Easily engaged travel clutch.
PROCESS LIMITATIONS
• The TANDEM CRUISER™ does not support open • Fully assembled for track use.
arc procedures. • High temperature rubber wheels for superior trac-
tion and heat resistance up to 500°F (260°C)
EQUIPMENT LIMITATIONS • Heavy duty slides for adjusting the electrode posi-
• Inductance of the electrode and work cables may tion in the joint.
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.

A-2
TANDEM CRUISER TM INSTALLATION

PARTS INCLUDED WITH THE TANDEM CRUISER™

Description Part No. Qty. Purpose

Flux Tube T10642-10 3 Connects from the bottom of the flux hopper to the
concentric cone flux nozzle.

Conduit Tubing S20023-5 2 Used for routing the electrode from the inlet bushing
to the wire drive. Trim the length as needed.

Wire Reel Enclosure M25007

2 Keeps the coils of electrode dry when the Cruiser is
M25386
2 stored in wet conditions.

Strain Relief Boot M17225 2 Covers the brass fitting of the wire reel enclosure to
keep water out.

Insulating Tube T7028-245 3 Used as connectors for joining the rubber flux tubes
together.

Nozzle Adapter M13739-1 2* Extends the nozzle 3.00”.

Nozzle Extension KP2721-1 2 Makes the nozzle longer.

Nozzle Extension, 45° curved KP2721-2 2 Frequently used when making horizontal fillet welds.

Nozzle Tip S10125-5/32 2 Contact tips for 5/32 wire.

Flux Hose Clamp T12929 2 Supports the rubber flux tube along the nozzle.

Nozzle Insulator T11807 2 Covers the nozzle or nozzle extensions to reduce

the potential of contact.

Flux Cone Nozzle Assembly M8249 1 These parts assemble together to direct the flux
T9078-1 1 around the electrode.
S10147 1
T10575-1 1
T10574 1

5/16-18 x 1.00 Bolt S24739-20

5/16 Lock Washers E106A-3 16 Used when assembling the Tandem Cruiser™ in the
flat fillet position.

5/16 Flat Washers S9262-121

5/16-18 x 2.50 Bolt CF000173 4

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

A-3
TANDEM CRUISER TM INSTALLATION

LOCATION • Contact Nozzle Assemblies

• Nozzle extensions
WARNING
• Contact Tips

ELECTRIC SHOCK can kill. Parts shown in red are at electrode potential.
(See Figure A.A)
• Do not touch the wire drive,
drive rolls, nozzle, wire coil,
assemble the TANDEM CRUISER™ to maintain safe
It is the responsibility of the user/builder/operator to
electrode or wire drive motor
when welding output is ON.
electrical clearances and to be stable.
Operate the TANDEM CRUISER™ only on stable and
• The tractor is an automatic
piece of equipment that may
be remotely controlled. dry surfaces.
• Turn the input power OFF at the disconnect Operating the TANDEM CRUISER™ on inclined sur-
switch or fuse box before attempting to connect faces requires adjusting and/or assembling the tractor
or disconnect input power lines, output cables or differently than shipped from the factory. Wire reel

top of the enclosure. Do not drive the TANDEM

control cables. enclosures must be installed with the wire exitting the

CRUISER™ up or down inclines steeper than 2

• Do not operate with covers, panels or guards
removed.
degrees.
Do not submerge the TANDEM CRUISER™.
• Do not let the electrode or wire spool touch the
tractor frame.

The TANDEM CRUISER™ is rated IP23S when the

• Only qualified personnel should perform this
installation.
wire reel enclosures are installed. It may be stored
• Insulate yourself from the work and ground. outdoors but is not intended for use during precipitation
• Always wear dry insulating gloves. unless sheltered.
------------------------------------------------------------------------ Protect the TANDEM CRUISER™ from preheat torches.

WARNING FIGURE A.A

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.
------------------------------------------------------------------------

tial and all other TANDEM CRUISER™ components.

Maintain clearance between parts at electrode poten-

Parts that are at electrode potential are:

• Wire
• Wire Spool
• Brass Conduit bushing adapter
• Wire Straightener Rolls
• 4 screw heads on back of the wire straighter.
• Feed plate and drive rolls

A-4
TANDEM CRUISER TM INSTALLATION

GENERAL ASSEMBLY
REMOVING THE BUTT JOINT GUIDE
WARNING
1. Loosen the bolts on the clamp as shown. Slide and
ELECTRIC SHOCK can kill. remove the butt joint guide kit.
• Improperly secured clamps FIGURE A.1 - BUTT JOINT GUIDE
and collars may shift, causing
Loosen bolts
parts at electrode potential to Slide and remove the butt joint kit
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.

2. Loosen the pendant clamp bolts. Slide the tube

• Failure to properly secure the clamps, collars,

supporting the pendant and flux hopper until it is

chains and lift bail may result in physical injury.

flush with the end of the clamp. Tighten all the

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

clamp bolts to 25 ft-lb.

FIGURE A.1a - BUTT JOINT GUIDE

A-5
TANDEM CRUISER TM INSTALLATION

Clamps FIGURE A.4 - CHAIN AND MAST ANCHOR

• Tighten clamp bolts to 25 ft-lbs (34 Nm).
• Use clamps with a key on horizontal tubes.
FIGURE A.1b - CLAMPS

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

driving the TANDEM CRUISER™ forward and may

Collars is 1/2” (12.7mm). Larger offsets increase the friction
• Tighten collar screw to 42 in-lbs (0.3 Nm) cause travel motor overcurrent errors and rapid wheel
FIGURE A.2 - COLLARS 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.
FIGURE A.5 - OUTRIGGERS

Clutch

Lift Bail
• Tighten lift bail hardware to 24 in-lbs (0.17 Nm). Do
not overtighten or the mast may become distorted.

FIGURE A.3 - LIFT BALE

The outriggers may be stacked to gain extra length.

Slide a T Nut (S28835) into the extrusion and then
insert a 1/4-20 bolt through the outrigger slots.
FIGURE A.6 - OUTRIGGERS EXTENSION

Chain and Mast Anchor

• The chain must be connected from the base to the
mast before lifting.
• Tighten all hardware as shown.

A-6
TANDEM CRUISER TM INSTALLATION

BUTT JOINT GUIDE, 2 WHEEL

(See Figure A.7)

Remove the butt joint guide assembly as shipped

from the factory. Loosen the clamp bolts on the
clamp holding the pendant tube. Slide the butt joint
guide out and set aside
FIGURE A.7

Then slide the pendant tube until it is flush with the

end of the clamp. Retighten the clamp bolts.
(See Figure A.8)
FIGURE A.8

A-7
TANDEM CRUISER TM INSTALLATION
Butt Joint Guide, 2 Wheel (See Figure A.9)

To assemble the butt joint guide,

• Support the Cruiser to remove weight from the front
wheels.
• Remove the front outrigger bar.
• Remove one of the front wheel assemblies by
removing the four bolts holding the wheel assembly
to the frame.
• Determine the number of spacer blocks required,
remove as necessary. The guide wheels should be
within 0.5 “ (12.7mm) of the weld wires when the
slides are at the mid position.
• Bolt the butt joint guide assembly to the frame,
using the set of holes that positions the guide
wheels as close as possible to the weld wires.
• Use the clamp to set the coarse vertical height. Set
the height so all three rubber wheels are touching
the ground when the butt joint guide is in the joint.
Tighten the clamp bolts to 25 ft-lbs (34 Nm)
• Use the fine vertical adjustment as necessary to
keep pressure on the guide wheels without lifting
the other rubber wheels off the ground.

FIGURE A.9 - BUTT JOINT, 2 WHEEL

A-8
TANDEM CRUISER TM INSTALLATION

FRONT WHEELS

In almost all configurations the front wheels must

remain parallel with the Cruiser base and rear wheels.
Improper adjustment of the front wheels will cause
inconsistent tracking of the joint, accelerate wheel
wear, poor operation on K396 track and may lead to
travel motor overload errors.
FIGURE A.10 FRONT WHEEL ADJUSTMENT

Only adjust the front wheels when welding a round

inside or outside seam 25 feet (7.6m) in diameter or
smaller. At all other times the front wheels must be set
to 90°.
FIGURE A.11 ADJUSTMENT 25 FEET DIA. OR SMALLER

To steer the front wheel to the left, loosen bolt A and

tighten bolt B to set the angle, then snug bolt A.

To steer the front wheel to the right, loosen bolt B and

tighten bolt A to set the angle, then snug bolt B.

FIGURE A.12 DIRECTION OF TRAVEL

A-9
TANDEM CRUISER TM INSTALLATION

LEVELING THE WHEELS

The frame mounting holes for bolting the front wheels

are oversized to allow for leveling of the front wheels.

To level the wheels: (See Figure A.12a)

WARNING
1. Turn off power at the welding power
source.

2. Place the tractor on a stable and level

surface.
3. Determine the axis that the tractor pivots.

FIGURE A.12a

4. While keeping both rear wheels in contact with

FIGURE A.12b

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
TANDEM CRUISER TM INSTALLATION

CROSS SLIDE AND WIRE DRIVE

Each slide has 4” (102mm) of travel.

When assembling the Cruiser, verify that no compo-

nents 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
TANDEM CRUISER TM INSTALLATION

WIRE REEL SPINDLE

• Position the wire reel spindle to prevent the reel and
electrode from contacting the tractor frame and
base.
• The wire reel spindle must be horizontal or oriented
upwards.
• The wire reel must not contact the frame.

FIGURE A.14 - WIRE REEL SPINDLE

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

A-12
TANDEM CRUISER TM INSTALLATION

WIRE REEL ENCLOSURE ASSEMBLY- WIRE REEL ENCLOSURE ASSEMBLY-

FOR CODES BELOW 12332 FOR CODE 12332 AND ABOVE

1. Determine the angular orientation of the wire reel 1. Remove the #10 screws and lockwashers from the
enclosure relative to the spindle clamp. To change spindle assembly using a 5/32" hex key.
the angle of the enclosure, remove the 6 bolts
securing the enclosure back to the mounting brack- 2. Use the same hardware to fasten the enclosure
et using a 7/16” wrench. Reassemble at the desire backing plate to the assembly.
angle, keep the gasket centered relative to the
enclosure back. Provisions are made to rotate the
3. For correct wire feeding, the flat portion of the
enclosure in 30° increments.
enclosure should be tilted toward the upright mast
FIGURE A.16 - ENCLOSURE ASSEMBLY of the Cruiser.

FIGURE A.17a - ENCLOSURE ASSEMBLY

BRACKET

GASKET

ENCLOSURE
BACK HARDWARE
SPINDLE
2. Unscrew the spindle brake and remove the spindle
brake parts and the spindle. ASSEMBLY
FIGURE A.17 - ENCLOSURE MOUNTING

ENCLOSURE HARDWARE
BACK

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.

A-13
TANDEM CRUISER TM INSTALLATION

4. Reassemble the spindle parts as shown (all codes).

FIGURE A.18 - SPINDLE PARTS

5. If required, swap the position of the ball bushing

assembly. Use a 7/16” wrench to loosen and tighten
the hardware.

6. Thread the conduit into the brass fitting on the ball

bushing assembly. Then slide the boot along the
conduit and over the brass fitting.

FIGURE A.19 - CONDUIT, BRASS FITTING, BOOT

7. When assembling the enclosure cover to the enclo-

sure back, verify the cover is evenly seated all the
way around.

A-14
TANDEM CRUISER TM INSTALLATION

50-60 LB. (22.7 - 27.2 KG)

FIGURE A.20 - COIL MOUNTING
COIL MOUNTING

WARNING

• Do not wear gloves during threading of wire or

changing wire spool.
------------------------------------------------------------------------

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

upper position.

2. With the coil reel assembly mounted to a 2" (51mm)

spindle, loosen the spinner nut and remove the
cover plate. Alternatively, lay the coil reel assembly
flat on the floor and loosen the spinner nut and
remove the cover plate.

3. Place the coil of electrode on the reel so it unwinds

from the bottom as it rotates.

4. Tighten the spinner nut as much as possible by

hand using the cover plate spokes for leverage. DO
NOT hammer on the spinner nut.

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

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

6. Be sure the coil is engaged with the spindle brake

pin and the release bar on the retaining collar "pops
up". The retaining collar must fully engage the
retaining groove on the spindle.

A-15
TANDEM CRUISER TM INSTALLATION

WIRE STRAIGHTENER ADJUSTMENT FEEDPLATE ROTATION

The wire straightener controls the amount of cast (or The feedplate of the wire drive may be rotated about
“curve”) in the wire. Excessive cast may effect align- the drive roll axis. Depending upon how the tractor is
ment of the wire in the joint. Too little cast may result assembled, rotating the feed plate will change the tilt
in insufficient wire contact in the contact tip. angle or the drag angle.
To adjust the wire straightener: 1. Turn off power at the welding power supply.
Tools required: 1/4” Hex Key 2. Loosen the set screw on the feedplate with a 5/16”
hex key.
1. Turn off power at the welding power source.
3. Rotate the feedplate to the new position. Do not
2. Loosen the two screws holding the wire straighten-
allow surfaces at electrode potential to touch the
er to the feed plate with a ¼” hex key.
frame, flux hopper, base or slides of the tractor.
FIGURE A.21 - WIRE STRAIGHTENER SCREWS
4. Tighten the set screw to secure the feedplate.
5. As equipped from the factory, the tractor is set-up
with “A” as the inlet and “B” as the outlet. To make
“B” the inlet and “A” the outlet, see the SET-UP
MENU parameter P.19.
FIGURE A.23 - FEEDPLATE ROTATION

3. Position the straightener as desired to remove or

add cast to the wire.
4. Tighten the screws holding the wire straightener to
the feed plate.
5. Turn power on at the welding power source.
6. Feed wire through the straightener. Adjust the
amount of pressure on the wire with the straighten-
er until the desired cast is achieved when the wire
exits the tip.

FIGURE A.22 - WIRE STRAIGHTENER

NOTE: A slight curvature to the wire helps to maintain

good electrical contact inside the contact tip.

A-16
TANDEM CRUISER TM INSTALLATION

FLUX HOPPER CABLES

The flux hopper may be mounted on either a horizontal ArcLink Control Cables
or vertical tube, or on the wire drive. For the best flow
ArcLink Control Cables are available in two forms:
of flux, keep the hose from the hopper to the nozzle as
vertical as possible. • K1543-xx series for most indoor or factory installa-
FIGURE A.24 - VERTICAL TUBE MOUNTING 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
FIGURE A.25 - HORIZONTAL TUBE MOUNTING 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.
For best operation, do not bundle the control cables
with the electrode cables.
FIGURE A.26 - ARCLINK CONTROL CABLES

E E
D A D A
C B C B

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

A-17
TANDEM CRUISER TM INSTALLATION

CABLE CONNECTIONS

FIGURE A.27 REAR AND FRONT VIEW CONNECTIONS

A-18
TANDEM CRUISER TM INSTALLATION

WELD CABLE SIZES

See Table A.1 for 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.
TABLE A.1

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

Percent CABLE SIZES FOR COMBINED LENGTHS OF ELECTRODE AND WORK

Duty CABLES
Amperes Cycle
0 to 50 Ft. 50 to 100 Ft. 100 to 150 Ft. 150 to 200 Ft. 200 to 250 Ft.
600 60 3/0 3/0 3/0 4/0 2-3/0
600 80 2-1/0 2-1/0 2-1/0 2-2/0 2-3/0
600 100 2-1/0 2-1/0 2-1/0 2-2/0 2-3/0
650 60 3/0 3/0 4/0 2-2/0 2-3/0
650 80 2-1/0 2-1/0 2-1/0 2-2/0 2-3/0
700 100 2-2/0 2-2/0 2-3/0 2-3/0 2-4/0
800 80 3-1/0 3-1/0 3-1/0 2-3/0 2-4/0
800 100 2-3/0 2-3/0 2-3/0 2-3/0 2-4/0
1000 80 2-4/0 2-4/0 2-4/0 2-4/0 4-2/0
1000 100 3-3/0 3-3/0 3-3/0 3-3/0 3-3/0
1200 80 3-4/0 3-4/0 3-4/0 3-4/0 3-4/0
1200 100 4-4/0 4-4/0 4-4/0 4-4/0 4-4/0
1500 80 4-4/0 4-4/0 4-4/0 4-4/0 4-4/0
1500 100 5-4/0 5-4/0 5-4/0 5-4/0 5-4/0

** Tabled values are for operation at ambient tempera-

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

A-19
TANDEM CRUISER TM INSTALLATION

SYSTEM SET-UP

The Tandem Cruiser is shipped from the factory config-

ured for butt weld joints and horizontal fillet joints. For
welding butt welds, assemble the straight nozzle exten-
sions to the nozzles. For welding horizontal fillet welds,
assemble the curved nozzle extensions to the nozzles.

FIGURE A.28 - SYSTEM SET-UP

K1811-xx

K1543-xx
k2683-xx

A-20
TANDEM CRUISER TM INSTALLATION
BUTT JOINTS
Butt Joint, Track Welding
• When operating on K396 track, change the wheel
size in the SET-UP menu to 5.65”.

FIGURE A.29 - BUTT JOINT TRACK WELDING

FILLET JOINTS
Horizontal Fillet
Uses KP2721-2 curved nozzle extension.
FIGURE A.30 - HORIZONTAL FILLET TRACK WELDING

A-21
TANDEM CRUISER TM INSTALLATION

FIGURE A.31 - FLAT FILLET (TROUGH)

A-22
TANDEM CRUISER TM INSTALLATION

7. Loosen the 8 bolts as shown, then rotate the upper

To configure the TANDEM CRUISER™ for Flat

structure 45°. Reassemble using the bolts that are

Fillet welding.

1. Turn off power at the power sources. 1.00” long. (See Figure A.32)

2. Remove the lift bail from the mast.

3. Disconnect the lead wire drive and laser cable, lead

electrode sense lead and trail wire drive cable.

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

5. Remove the slide assembly from the Cruiser mast.

Remove the collar from the mast.

6. Remove the boom and spindle assembly.

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

TILT MAST
See Step 8

TANDEM FLAT

A-23
TANDEM CRUISER TM INSTALLATION
8. Reposition the clamp on the slide assembly in a ver-
tical orientation, and reverse the orientation of the
wire drive bracket.
FIGURE A.33

9. Mount the wire drive holders as shown. Use 3 spac-

ers to lower the trail wire drive holder and assemble
using the 5/16-18 x 2.50 bolts.
FIGURE A.34

A-24
TANDEM CRUISER TM INSTALLATION

10. Mount the slide assembly to the Tandem Cruiser

base and frame.
FIGURE A.35

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

screw, rotating the head, and then tightening the
set screw
FIGURE A.36

SET SCREW

A-25
TANDEM CRUISER TM INSTALLATION

12. Swap the position of the wire straightener on both

wire drives. Assemble a 3” extension to the trail
wire, and the lead wire drive if required.

FIGURE A.37

LEAD WIRE DRIVE TRAIL WIRE DRIVE

13. Assemble the wire drives to the brackets.

Assemble the nozzles and nozzle extensions.
FIGURE A.38

A-26
TANDEM CRUISER TM INSTALLATION

14. Place the collar and boom assembly on the Tandem Cruiser.
FIGURE A.39

Important: Position the tube on the boom to prevent

both wire drives from contacting the frame when the
horizontal slide is adjusted. Position the spindles to
prevent the wire coils from touching the frame, slides,
or work piece.
FIGURE A.40

A-27
TANDEM CRUISER TM INSTALLATION

13. Assemble the lift bail.

FIGURE A.39

A-28
TANDEM CRUISER TM INSTALLATION

BASE DIMENSIONS ONLY

A-29
TANDEM CRUISER TM OPERATION

SAFETY PRECAUTIONS • Only qualified personnel should install, use or

service this equipment.
WARNING ------------------------------------------------------------------------
ELECTRIC SHOCK can kill. The serviceability of a product or structure utiliz-
ing the welding programs is and must be the sole
• Turn the input power OFF at
responsibility of the builder / user. Many variables
the disconnect switch before
beyond the control of The Lincoln Electric
working on this equipment.
Company affect the results obtained in applying
• Do not touch electrically hot parts. these programs. These variables include, but are
• Only qualified personnel should install, use or not limited to, welding procedure, plate chemistry
service this equipment. and temperature, weldment design, fabrication
• Do not allow parts at electrode potential to touch methods and service requirements. The available
the tractor frame, cress slides, base flux hopper range of a welding program may not be suitable for
or other parts. all applications, and the build / user is and must be
solely responsible for welding program selection.
• Disengaging the clutch does not stop the weld-
ing arc. PRODUCT DESCRIPTION
The TANDEM CRUISER™ is designed to weld with
• Always wear dry insulating gloves.
both the lead and trail arcs. If desired, only the lead
arc may be used. It can also be used with just the trail
------------------------------------------------------------------------

arc when using MANUAL travel.

WARNING
By default, the lead and trail arc are triggered indepen-
MOVING PARTS can injure.

dently. Change P23 through the set-up menu to have

• Do not leave the tractor unat-
both arcs trigger from the lead start and stop buttons.
tended while it is welding or

Operation of the lead and trail arc is similar.

traveling.

Differences are:
• Electrode reel, drive rolls and wire straightener

• No travel commands for the trail arc.

rolls turn during welding or inching.
• Keep gloved hands away from rotating parts.
• The lead arc has 4 memories, the trail arc has 8
memories.
• Keep away from pinch points.
• Do not place the tractor on inclined surfaces with
the clutch disengaged.
GRAPHIC SYMBOLS

Wire Feed

B-1
TANDEM CRUISER TM OPERATION

FIGURE B.1 - PENDANT CONTROLS LEAD ARC

TANDEM C

FIGURE B.2 - PENDANT CONTROLS, TRAIL ARC

CRUISER

B-2
TANDEM CRUISER TM OPERATION

MOVING THE TRACTOR

The tractor will not travel unless the clutch is engaged.
To engage the clutch, rotate the handle upwards. To
disengage the clutch, rotate the handle to the 3 o’clock
position.
The travel speed is adjustable from 7 to 100 in/min
(1.78 to 2.54 m/min). From 7 to 20 in/min, the travel
speed may be set in 0.5 inch/min increments. Above
20 in/min, the travel speed adjusts at 1.0 inch/min
increments.
To drive the tractor without welding:
FIGURE B.3 - ENGAGE THE CLUTCH

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

FIGURE B.4 - TRAVEL DIRECTION

2. Select either forward or reverse travel on the pen-

dant.
FIGURE B.5 - JOB BUTTON, TOGGLE SWITCH

3. Press and hold the jog button, or place the toggle

switch in the MANUAL travel position.

B-3
TANDEM CRUISER TM OPERATION

When power is first applied to the TANDEM

LASER POINTER POWER-UP SEQUENCE

CRUISER™ the MODE SELECT Display reads “TAN-

DEM CRUISER™ Initializing...”. Once the Power
CAUTION
Wave AC/DC has initialized (20 to 60 seconds) a
• Class II laser radiation present. Do not stare “lamp test” is performed.
into laser beam or view directly with optical
instruments. • All discrete LED’s, seven segment displays and
------------------------------------------------------------------------ alpha numeric displays will be turned ON for 2 sec-
Laser pointer is used to aid in guiding the TANDEM
onds.

CRUISER™. The laser pointer mounts to the nozzle or

• After 2 seconds all displays are turned OFF again
and the MSP Display will show:
nozzle extensions. Align the wire in the joint, then posi-
tion the laser pointer approximately 3” (76mm) in front FIGURE B.6 - MSP DISPLAY
of the wire, also pointing into the joint.

Turn the laser off when not welding.

TOUCH SENSE

WARNING After initialization is complete, the MSP Display will

show the weld mode. The upper displays will show the
ELECTRIC SHOCK can kill. parameters that were selected when the machine was
• If the Touch Sense is enabled, the last powered down and the WELD MODE Indicator will
Power Source output is ON as long be ON.
as the Feed Forward button is held.
FIGURE B.7 - WELD MODE INDICATOR
Avoid touching any portion of the
weld circuit while feeding.
------------------------------------------------------------------------
The touch sense option, when enabled, allows the
operator to feed the wire forward until it touches the
workpiece. When contact to the work is made, the wire
will stop.

If the touch sense option is disabled, the wire is “cold”

during the Feed Forward time. It will not stop when it
touches the work.

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

Section)

B-4
TANDEM CRUISER TM OPERATION

WIRE FEEDER SETUP CHANGING AND SETTING WELD MODES

WARNING To select a weld mode, press the WELD MODE
SELECTOR button until the WELD MODE indicator
comes ON (it may already be lit by default at power
ELECTRIC SHOCK can kill. up). Turn the control knob to select the desired mode.
• Prior to inserting the wire, dis- After about 1 second, the parameters for the new
able “Touch Sense” (P.15 in mode will be displayed. These parameters can be
the Setup Menu). adjusted with the control knobs below each display.
FIGURE B.10 - SETTING WELD MODES

------------------------------------------------------------------------
Use the FEED FORWARD pushbutton to insert wire
into the feed mechanism.
While pressing either the FEED FORWARD or FEED
REVERSE pushbutton the MSP Display will read as
shown and the preset wire feed speed will be displayed
on the left (AMPS/WFS) display.
FIGURE B.8 - FEED SPEED DISPLAY

NOTE: CC Modes will show AMPS in the upper left

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

FREQUENCY
Press the WELD MODE selector until the FREQUEN-
CY/ BALANCE indicator comes ON and the MSP
Display reads “Frequency”. If the selected mode allows
for frequency adjustment, the Control Knob can be
The feed speed can be changed by adjusting the con-
used to select the desired frequency between 10 and
trol knob below the display while pressing either but-
100hz.
ton. Use FEED REVERSE to retract the wire from the
FIGURE B.11 - FREQUENCY
feed mechanism. FEED FORWARD feeds the wire
downward toward the work piece.
The TANDEM CRUISER™ has an option in the Setup
Menu (P.15) to enable the “Touch Sense” circuitry.
See the Setup Menu. When P.15 is enabled and the
FEED FORWARD button is pressed, the MSP Display
will read:
FIGURE B.9 - HOT FEED FEATURE

WARNING: This “Hot Feed” feature enables the

output of the power source and there is voltage on Frequency adjustment can be used to fine tune stabil-
the wire while feeding down. Avoid touching any ity of imbalanced waveforms and multiple arc system.
exposed parts as defined in the SAFETY PRECAU-
TIONS.

B-5
TANDEM CRUISER TM OPERATION

BALANCE ADJUST OFFSET ADJUST

Press the WELD MODE selector until the MSP Display reads Press the WELD MODE selector until the MSP Display reads
“Balance”. If the selected mode allows for balance adjust- “Offset”. If the selected mode allows for offset adjustment,
ment, the Control Knob can be used to select the desired the Control Knob can be used to select the desired offset.
wave balance through a range of 25% to 75%. The amount of offset allowed is determined by the selected
FIGURE B.12 - BALANCE ADJUST weld mode.
FIGURE B.13 - OFFSET ADJUST

DECREASED BALANCE INCREASED BALANCE

More Penetration Less Penetration
Less Desposition More Desposition
POSITIVE OFFSET
More Penetration
Less Desposition
NEGATIVE OFFSET
Less Penetration
More Desposition

NEUTRAL BALANCE

Adjusting the Balance (the ratio between Positive and NEUTRAL OFFSET

Negative half cycle ‘on time’) changes the deposition for

more efficient welding.

WELD SEQUENCE (See Figure B.14) Independent control of the Positive and Negative cycles
allows for more precise control of penetration and deposition.
The weld sequence defines the weld procedure from beginning to
end. All adjustments are made through the user interface. They control run-in (speed at which the wire approaches the work-
piece) and provide the power to establish the arc. Typically output
START OPTIONS levels are increased, and WFS is reduced during the strike portion
of the weld sequence.
The delay, strike, start and upslope parameters are used at the
beginning of the weld sequence to establish a stable arc and provide • START values allow the arc to become stabilized once it is estab-
a smooth transition to the welding parameters. They are described lished. Extended start times or improperly set parameters can
in the following: result in poor starting.

• ARC DELAY inhibits the wire feed for up to 5 seconds to provide • UPSLOPE TIME determines the amount of time it takes to ramp
an accurate weld start point. Typically used in multi-arc systems. from the start parameters to the weld parameters. The transition is
linear and may be up or down depending on the relationship
• STRIKE settings are valid from the beginning of the sequence between the start and weld settings.
(Start) until the arc is established.
FIGURE B.14 - WELD SEQUENCE

B-6
TANDEM CRUISER TM OPERATION

START OPTIONS OPERATION • RESTRIKE TIME determines how long the system
will try to re-establish the arc in the event of a poor
Pressing the Arc Start/End Options pushbutton will start or if the arc goes out for any reason (short cir-
illuminate the START OPTIONS LED and the Arc cuit or open circuit). During restrike, the WFS and
Delay Time parameter will show on the MSP Display. outputs are driven in an attempt to re-establish the
FIGURE B.15 - START OPTIONS OPERATION arc.
• A restrike time of 1 to 2 seconds is sufficient
in most applications.
• A restrike time of 0 seconds allows the
restrike function to continue indefinitely.

END OPTIONS OPERATION

Pressing the Arc Start/End Options pushbutton after
Use the Mode Select Panel Control to select the scrolling through the Start Options will illuminate the
desired delay time. Press the Weld Mode Selector to END OPTIONS LED and the Downslope Time para-
exit the Start parameters. Repeated pressing of the meter will show on the MSP Display.
Arc Start/End Options pushbutton will scroll through FIGURE B.16 - END OPTIONS OPERATION
the parameters. Turning the Mode Select Panel
Control, while on a parameter will change its value.
When a Start Option is set to a value other than OFF,
the START OPTIONS LED will blink synchronous with
the WFS or Amps and/or the Volts LED located on the
Dual Display Panel prompting the user to enter these
parameters. The parameters that can be set by the
user in the START OPTIONS will be as follows:
ARC DELAY TIME
STRIKE WFS Use the Mode Select Panel Control to select the
STRIKE TIME desired delay time. Press the Weld Mode Selector to
START WFS/AMPS exit the End parameters. Repeated pressing of the Arc
START VOLTS Start/End Options pushbutton will toggle through the
START TIME parameters. Turning the Mode Select Panel Control
UPSLOPE TIME while on a parameter will change its value. When the
Crater Time is set to a value other than OFF, the END
OPTIONS LED will blink synchronous with the WFS or
END OPTIONS Amps LED (depending on CC or CV Weld Modes) and
with the Volts LED located on the Dual Display Panel
The downslope, crater, and burnback parameters are prompting the user to enter these parameters. The
used to define the end of the weld sequence. They are parameters that can be set by the user in the END
defined in the following: OPTIONS will be as follows:
• DOWNSLOPE determines the amount of time it DOWNSLOPE TIME
takes to ramp from the weld parameters to the crater CRATER WFS/AMPS
parameters. The transition is linear and may be up or CRATER VOLTS
down depending on the relationship between the CRATER TIME
weld and crater settings. BURNBACK TIME
• CRATER parameters are typically used to fill the RESTRIKE TIME
crater at the end of the weld and include both time
and output settings.
• BURNBACK defines the amount of time the output
remains on after the wire has stopped. This feature
is used to prevent the wire from sticking in the weld
puddle and to condition the end of the wire for the
next weld. A burnback time of 0.4 second is sufficient
in most applications.

B-7
TANDEM CRUISER TM OPERATION

MEMORIES LIMITS
The TANDEM CRUISER™ has 4 memories. Each Limits allow the welder to adjust the welding procedure
memory stores : only within a defined range.
• Weld Mode Each memory may have a different set of limits. For
• Amperage (or WFS) example, memory 1 may limit the WFS to 100 through
• Voltage 120 in/min, and memory 2 may limit the WFS to 140
• Travel Speed through 160 in/min, while memory 3 may have no WFS
• Frequency limits.
• Balance
Parameters are constrained by machine limits, or by
• DC Offset
setting memory limits. When memory limits are
• Arc Start Options
enabled, the parameter will flash whenever an attempt
• Arc End Options
is made to exceed the memory limit value. The para-
meter will not flash if an attempt is made to exceed the
FIGURE B.17 - MEMORIES machine limit.
FIGURE B.18 - LIMITS
Limits may be set for:
Wire Feed Speed
Voltage
Amperage
Travel Speed
Frequency
Balance
DC Offset
Arc Start Options
Arc End Options

Weld modes cannot be selected through the Limits

Recall a memory with memory buttons Setup menu, and must be chosen and saved to mem-
ory before entering the Limits Setup Menu.
To recall a memory, press one of the four memory but-
tons. The memory is recalled when the button is
released. Do not hold the button for more than two sec-
onds.
Save a memory with memory buttons
To save a memory, press and hold the desired memo-
ry button for two seconds. When the button is initially
pressed, the corresponding LED will illuminate. After
two seconds, the LED will turn off. Do not hold the but-
ton for more than 5 seconds when saving a user mem-
ory.
Note that memories may be locked in the set-up menu
to prevent accidental overwrite of the memories. If an
attempt is made to save a memory when memory sav-
ing is locked, the message "Memory save is Disabled!"
will appear briefly in the MSP4 display.

B-8
TANDEM CRUISER TM OPERATION

To set limits, press the desired memory button 1-8 and The Limits Setup menu shows a list of all parameters
hold for 5 seconds. Release the memory button when available for the weld mode stored in the memory cho-
the LED begins to blink rapidly and the MSP4 displays sen
"Memory X Set Limits" as shown below.
To lock a parameter to a specific value that cannot
FIGURE B.19 - MEMORY SET LIMITS be changed, set the high and low limits to the same
value.
The memory value must always be less than or equal
to the high limit, and greater than or equal to the low
limit.
After setting limits, press the memory button with the
flashing LED. The MSP4 will ask to save or discard the
limit changes just made. Press the left MSP4 for button
(YES) to save and enable the limits and exit. Press the
FIGURE B.20 - MEMORY SET LIMIT DISPLAY right MSP4 button (NO) to exit and leave limits
HIGH MEMORY LOW unchanged.
LIMIT VALUE LIMIT
ENABLING/DISABLING LIMITS
FIGURE B.22 - ENABLING LIMITS

PARAMETER
NAME

SETUP will illuminate on the MSP4 panel and the dis-

play will show the following:
Four items show on the MSP4 panel. Limits for each memory may be enabled or disabled by
• Memory Value pressing and holding the appropriate memory button
• High Limit for 10 seconds. Release the memory button when the
• Low Limit MSP4 display shows the following:
• Parameter Name FIGURE B.23 - ENABLE/DISABLE LIMITS

One of these items will flash to indicate which item will

change when the MSP4 encoder is rotated. Press the
right button on the MSP4 panel to select the item to
change.
FIGURE B.21 - MSP4 PANEL

B-9
TANDEM CRUISER TM OPERATION

SETUP will light and the MSP4 displays the following:

FIGURE B.24 - ENABLE/DISABLE LIMITS
DISPLAY

Press the left MSP4 button (YES) to enable limits or

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

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

All the DIP switches are in the OFF position. All the DIP switches are in the OFF position.
Travel Board DIP Switches Lead Wire Drive Board DIP Switches

1 2 3 4 5 6 7 8
ON
OFF
8 7 OFF
6 5
4 3 ON
2 1

All the DIP switches are in the OFF position.

Trail Wire Drive Board DIP Switches
8
7
6
5
4
3
2
1
ON
F
OF

B-10
TANDEM CRUISER TM OPERATION

SET-UP FEATURES MENU

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

PARAMETER DEFINITION
P.1 through P.99 Unsecured Parameters (always adjustable)
P.101 through P.199 Diagnostic Parameters (always read only)
P.501 through P.599 Secured Parameters (only accessible with Weld Manager)
To access the set-up menu, press the right and left buttons of the MSP4 panel simultaneously. Note that the set-
up menu cannot be accessed if the system is welding, or if there is a fault (The status LED is not solid green).
Change the value of the blinking parameter by rotating the SET knob.
To exit the set-up menu at any time, press the right and left buttons of the MSP4 panel simultaneously. Alternately,
1 minute of inactivity will also exit the set-up menu.

PARAMETER DEFINITION
P.0 Press the left button to exit the set-up menu.

This option selects which units to use for displaying wire feed speed.
P.1 Wire Feed Speed Units

English = inches/minute wire feed speed units (default).

Metric = meters/minute wire feed speed units.

This option selects what value will be shown on the upper left display while
Arc Display Mode
P.2
welding.
Amps = The left display shows Amperage while welding (default).
WFS = The left display shows Wire Feed Speed while welding.

This setup parameter was previously named "Display Energy"

P.3 Display Options

If the previous software revision had this parameter set to display energy, that
selection will remain.

This option selects the information displayed on the alphanumeric displays

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

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

B-11
TANDEM CRUISER TM OPERATION

PARAMETER DEFINITION

Press the Right Button to enter the option and rotate the Control Knob to select
Tractor Wheel Size

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

Press the Right Button to enter the option and rotate the Control Knob to select
Tractor Travel Speed

Travel Speed. Press the Right Button to enter the selected option. Rotate the
Control Knob to select the desired value. After selecting the value, press the
Left Button to save the value and back out to select another option. Rotate the
Control Knob to make another selection, or press the Left Button to exit this
P.12 option.

This option allows the adjustment of the start and end travel options for a travel
Travel Carriage Start/Stop - Travel Starts

carriage. Press the Right Button to enter the option and rotate the Control
Knob to select either starting or ending options. Press the Right Button to enter
the selected option. Rotate the Control Knob to select the desired function.
After selecting the function, press the Left Button to save the function and back
out to select another option. Rotate the Control Knob to make another selec-
tion, or press the Left Button to exit this option.

This option allows the adjustment of the start and end travel options for a travel
Travel Carriage Start/Stop - Travel Ends

carriage. Press the Right Button to enter the option and rotate the Control
Knob to select either starting or ending options. Press the Right Button to enter
the selected option. Rotate the Control Knob to select the desired function.
After selecting the function, press the Left Button to save the function and back
out to select another option. Rotate the Control Knob to make another selec-
tion, or press the Left Button to exit this option.

B-12
TANDEM CRUISER TM OPERATION

PARAMETER DEFINITION

Use this option to reset the initial weight of the consumable package. Press
P.14 Reset Consumable Weight

the Right Button to reset the consumable weight. This option will only appear
with systems using Production Monitoring.

This option allows enabling or disabling touch sense when feeding wire for-
P.15 Cold-Inch Touch Sense Option

ward.
Disabled = Touch sensing is disabled when feeding the wire forward
(default).
Enabled = Touch sensing is active when feeding the wire forward.

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

This option selects the Wire Drive Gear Ratio that will be used. The possible
P.18 Wire Drive Gear Ratio.

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

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

This option selects the direction that the Wire Drive will run in. This option is
P.19 Wire Drive Direction

useful since the Tractor's WD head can be rotated to "point" in different direc-
tions.

This option allows selection of the Shutdown 2 input function on the control
P.21 Shutdown 2 Function Select

box.
Normal Shutdown = The Shutdown 2 input functions as a standard shutdown
input that locks out all input buttons (default)
Output Disable = The Shutdown 2 input functions as a machine output lock-
out to disable the welding circuit but still allow cold feeding of the wire.

For Sub-Arc Lead Arc machines only. Allows the Lead Arc User Interface to
P.23 Trigger Fan-Out

control all machine triggers in a multi-arc system.

No = Only the machine connected to the User Interface can be triggered on
and off (default).
Yes = All machines in the system can be triggered on and off simultaneous-
ly.

B-13
TANDEM CRUISER TM OPERATION

PARAMETER DEFINITION

Use this option for diagnostic purposes only. When power is cycled, this
P.80 Sense from Studs.

option is automatically reset to False.

False = Voltage sensing is automatically determined by the selected weld
mode and other machine settings (default).
True = Voltage sensing is forced to "studs".

Most power sources contain weld modes used for calibration and test purpos-
P.99 Show Test Modes

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

Diagnostics are only used for servicing or troubleshooting the Power Wave
P.100 View Diagnostics

system. Select "Yes" to access the diagnostic options in the menu. Additional
parameters will now appear in the setup menu (P.101, P.102, etc).

Used for viewing all the system event logs. Press the Right Button to enter the
P.101 Event Logs

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

Used for viewing all the system fatal logs. Press the Right Button to enter the
P.102 Fatal Logs

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

Used for viewing the software versions for each board in the system. Press
P.103 Software Version

the Right Button to enter the option. Rotate Control Knob to select the desired
board to read. Press the Right Button again to read the firmware version.
Press the Left Button to back out to select another board. Rotate the Control
Knob to select another board, or press the Left Button to exit this option.

Used for viewing the hardware version for each board in the system. Press
P.104 Hardware Version

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

B-14
TANDEM CRUISER TM OPERATION

PARAMETER DEFINITION

Used for viewing the Weld Set in the Power Source. Press the Right Button
P.105 Welding Software

to read the Weld Set version. Press the Left Button to back out and exit this
option.

Used for viewing the IP address of Ethernet compatible equipment. Press the
P.106 Ethernet IP Address

Right Button to read the IP Address. Press the Left Button to back out and
exit this option. The IP address cannot be changed using this option.

Used for viewing the type of power source the feeder is connected to. Press
P.107 Power Source

the Right Button to identify the power source as either LincNet or ArcLink.
Press the Left Button to back out and exit this option.

Originally used to prevent inadvertent changes of secure setup parameters,

P.500 View Lockout Parameters

P.500 was previously used as a gateway to these parameters. Presently, this

option does not exist in any setup menu.

B-15
TANDEM CRUISER TM ACCESSORIES

OPTIONAL KITS AND ACCESSORIES

DRIVE ROLL AND GUIDE TUBE KITS

ITEM K# DESCRIPTION
1 K1733-5 Wire Straightener
KP1899-1 Drive Roll/ Guide Tube Kit, 3/32-7/32 1
2 KP1899-2 Drive Roll/ Guide Tube Kit, 1/16, 5/64, 3/32
KP1899-3 Drive Roll/ Guide Tube Kit, 035, 045, 052
KP1899-4 Drive Roll/ Guide Tube Kit, 045, 052 cored
K231-5/64 Contact Nozzle Assembly, 5/64 (2.0mm)
K231-3/32 Contact Nozzle Assembly, 3/32 (2.4mm)
3 K231-1/8 Contact Nozzle Assembly, 1/8 (3.2mm)
K231-5/32 Contact Nozzle Assembly, 5/32 (4.0mm)
K231-3/16 Contact Nozzle Assembly, 3/16 (4.8mm)
K231-7/32 Contact Nozzle Assembly, 7/32 (5.6mm)
4 KP2721-1 Nozzle Extension, 5”
KP2721-2
T12929
Nozzle Extension, 45º Curved
Flux Hose Clamp
2
T11807 Nozzle Extension Insulator
KP1962-3B1 Contact Tip, 3/32
KP1962-1B1 Contact Tip, 1/8
5 KP1962-4B1 Contact Tip, 5/32
KP1962-2B1 Contact Tip, 3/16
KP1962-5B1 Contact Tip, 7/32
K148A or Positive Contact Nozzle Assembly
K148B
K285 Concentric Flux Cone Assembly to use with 3
K148A or K148B

K231 nozzles are rated up to 600 Amps

K148 nozzles are rated up to 1000 Amps

C-1
TANDEM CRUISER TM ACCESSORIES

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

aluminum splined tube;
one 15” aluminum splined
tube; one 30” steel tube; 8
clamp assemblies with
keys; 2 outrigger
assemblies; hardware.
K3089-1 Cross Slide Assembly Includes: two slides with 4
inches of travel. (1 cross
slide assembly included
with each tractor.)
K1733-5 Wire Straightener Includes: A three roll wire
straightener with
adjustable pressure. (1
included with each tractor)
K396 Track Section Includes: a single section
of 70 in (1.8m) of track.
K3070-1 Tiny Twin Kit for the Includes: 2 nd spindle, drive
tractor rolls, 95:1 gears.
KP3095-1 Conduit Includes: 5 feet (1.5m) of
black conduit.
K1543-xx ArcLink Control Cable Includes: 5 pin to 5 pin
tractor to power source
control cable. Cables may
be connected end-to-end to
make a longer cable.
Connectors are black
anodized aluminum.
K2683-xx ArcLink Control Cable, Includes: 5 pin to 5 pin
Heavy Duty tractor to power source
control cable. Cables may
be connected end-to-end to
make a longer cable.
Female connector is a
brass spin nut. Male
connector is made from
stainless.
K1504-1 60 lb Coil Adapter Includes: one coil adapter
for use with 2” spindles.

Accessories Included with the TANDEM

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

Does not include a control cable.

C-2
TANDEM CRUISER TM MAINTENANCE

SAFETY PRECAUTION CALIBRATION SPECIFICATION

There is no wire feed speed calibration adjustment for

WARNING Wire Feed Speed

ELECTRIC SHOCK can kill. the Cruiser.

To validate wire feed speed:

• Do not touch electrically live parts
• Turn off Touch Sensing with P15 in the Set-Up
such
Menu.
as output terminals or internal
• Adjust the wire feed speed to 100 in/min (2.54
wiring.
m/min)
• Inch the wire down and measure the actual wire feed
• When inching with gun trigger, electrode and
speed with a calibrated wire feed speed tachometer.
drive mechanism are “hot” to work and ground
(K283)
and could remain energized several seconds
• The measured wire feed speed should be within 98
after the gun trigger is released.

• Turn OFF input power at welding power source to 102 in/min (2.49 to 2.59 m/min) [±2%]
before installation or changing drive roll and/or
When using the K396 track, the P12 Wheel size para-
guide tubes. Travel Speed

• Welding power source must be connected to meter should be set to 5.65 in.

To validate and calibrate travel speed:

system ground per the National Electrical Code
• Set the Travel Speed to 30 in/min (7.6 m/min)
or any applicable local codes.

• Only qualified personnel should • Engage the clutch and use the manual travel speed
switch to travel the tractor for 60 seconds.
• Measure the distance traveled.
perform maintenance work.
• Adjust P12 Wheel Size in the Set-up menu as fol-
lows
Observe all additional Safety Guidelines detailed

Example: Set travel speed = 30 in/min

throughout this manual.

Actual travel speed = 29 in/min

Existing P12 wheel size = 6.00 in
• Check the weld cables and control cables for cuts
ROUTINE MAINTENANCE

• Blow out the slides. 6.00in.

New P12 Wheel Size = x 29in. = 5.80in.
30in.

• Every 6 months, check wire drive motor brushes.

PERIODIC MAINTENANCE

Replace them if they are less than 1/4” (6mm) long.

• Every 6 months, lubricate the front axles.
• Every 12 months, inspect the wire drive gearbox and
coat the gear teeth with moly-disulfide grease. DO
NOT use graphite grease.

D-1
TANDEM CRUISER TM TROUBLESHOOTING

HOW TO USE TROUBLESHOOTING GUIDE

WARNING
Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician and
machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical
Shock, please observe all safety notes and precautions detailed throughout this manual.
__________________________________________________________________________
This Troubleshooting Guide is provided to help you Step 3. RECOMMENDED COURSE OF ACTION
locate and repair possible machine malfunctions. This column provides a course of action for the
Simply follow the three-step procedure listed below. Possible Cause, generally it states to contact your
local Lincoln Authorized Field Service Facility.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled “PROBLEM (SYMP- If you do not understand or are unable to perform the
TOMS)”. This column describes possible symptoms Recommended Course of Action safely, contact your
that the machine may exhibit. Find the listing that local Lincoln Authorized Field Service Facility.
best describes the symptom that the machine is
exhibiting.

Step 2. POSSIBLE CAUSE.

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

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

E-1
TANDEM CRUISER TM TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE RECOMMENDED
(SYMPTOMS) CAUSE COURSE OF ACTION
A wire drive motor overload occurs. 1. Examine the contact tip for wear
(Error 81) and proper size. Replace as
necessary.
2. Verify the correct drive rolls and
inner wire guide are installed in
the wire drive.
3. Do not use more idle roll pres-
sure than necessary. Check for
proper setting.
4. Verify that the wire pulls easily
through the take-off arm bushing
and conduit.
5. Check that the wire straightener
is not exerting excessive load on
If all recommended possible areas

the wire.
of misadjustment have been

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

checked and the problem persists,

95:1 or 142:1
Contact your local Lincoln

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

Authorized Field Service Facility.

142:1.

A travel motor overload occurs. 1. Verify the Cruiser rolls freely

(Error 81) when the clutch is disengaged.
2. Check for excessive loads
caused by dragging long cables.
3. When using the outriggers to
steer the Cruiser, set the offset
between the front and rear out-
riggers at 0.5” (12.7mm).
4. Verify the front wheels are per-
fectly straight.

Error 215 1. Check that all of the DIP switch-

es on the travel drive board and
the wire drive board are in the
OFF position.

Frequency and Balance do not 1. Verify a AC square wave weld

appear on the display. mode has been selected.

The wire feeder does not feed wire 1. Verify the power source is
and the drive rolls do not spin. turned on.
2. Verify the circuit breaker for the
wire feeder power (on the power
source) has not tripped.
3. Verify power is being supplied
to the wire feeder.
4. Check that any equipment con-
nected to the external shut-off
inputs has not faulted.

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

E-2
TANDEM CRUISER TM TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENTS(S) COURSE OF ACTION
The wire drive feeds wire in the 1. Change P19 wire feed direction
wrong direction. parameter in the Set-Up menu.

The wire drive speed is incorrect. 1. Verify the gear ratio of the wire
drive and P18 match.

When the welding arc is activated, 1. Check all electrode and work
the drive rolls spin but no arc is pre- connections.
sent.

If all recommended possible areas

of misadjustment have been
checked and the problem persists,
Contact your local Lincoln
Authorized Field Service Facility.

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

E-3
 TANDEM CRUISER TM

F-1
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the
machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.
DIAGRAMS
 TANDEM CRUISER TM

F-2
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the
machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.
DIAGRAMS
 NOTES

F-3
CUSTOMER ASSISTANCE POLICY
The business of The Lincoln Electric Company is manufacturing and
selling high quality welding equipment, consumables, and cutting
equipment. Our challenge is to meet the needs of our customers and
to exceed their expectations. On occasion, purchasers may ask
Lincoln Electric for advice or information about their use of our
products. We respond to our customers based on the best information
in our possession at that time. Lincoln Electric is not in a position to
warrant or guarantee such advice, and assumes no liability, with
respect to such information or advice. We expressly disclaim any
warranty of any kind, including any warranty of fitness for any
customer’s particular purpose, with respect to such information or
advice. As a matter of practical consideration, we also cannot assume
any responsibility for updating or correcting any such information or
advice once it has been given, nor does the provision of information
or advice create, expand or alter any warranty with respect to the sale
of our products.
Lincoln Electric is a responsive manufacturer, but the selection and
use of specific products sold by Lincoln Electric is solely within the
control of, and remains the sole responsibility of the customer. Many
variables beyond the control of Lincoln Electric affect the results
obtained in applying these types of fabrication methods and service
requirements.
Subject to Change – This information is accurate to the best of our
knowledge at the time of printing. Please refer to
www.lincolnelectric.com for any updated information.

TABLE OF CONTENTS
INSTALLATION
OPERATION
ACCESSORIES
MAINTENANCE
TROUBLESHOOTING
DIAGRAMS