WEB SITE: OPERATOR S MANUAL

Transcription

1 WEB SITE: IM946-A August, 2010 This manual covers equipment which is no longer in production by The Lincoln Electric Co. Specifications and availability of optional features may have changed. CRUISER TRACTOR For use with machines having Code Numbers: Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation... and thoughtful operation on your part. DO NOT INSTALL, OPER- ATE OR REPAIR THIS EQUIP- MENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CON- TAINED THROUGHOUT. And, most importantly, think before you act and be careful. IEC OPERATOR S MANUAL Copyright Lincoln Global Inc. World's Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland, Ohio U.S.A. TEL: FAX:

2 Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. The Above For Diesel Engines FOR ENGINE powered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors. 1.c. Do not add the fuel near an open flame welding arc or when the engine is running. Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting. Do not spill fuel when filling tank. If fuel is spilled, wipe it up and do not start engine until fumes have been eliminated. 1.d. Keep all equipment safety guards, covers and devices in position and in good repair.keep hands, hair, clothing and tools away from V-belts, gears, fans and all other moving parts when starting, operating or repairing equipment. 1.e. In some cases it may be necessary to remove safety guards to perform required maintenance. Remove guards only when necessary and replace them when the maintenance requiring their removal is complete. Always use the greatest care when working near moving parts. 1.f. Do not put your hands near the engine fan. Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running. SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. The Above For Gasoline Engines 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 , Miami, Florida or CSA Standard W A Free copy of Arc Welding Safety booklet E205 is available from the Lincoln Electric Company, St. Clair Avenue, Cleveland, Ohio BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PER- FORMED ONLY BY QUALIFIED INDIVIDUALS. 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. 1.g. To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work, disconnect the spark plug wires, distributor cap or magneto wire as appropriate. 2.d.4. Connect the work cable to the workpiece as close as possible to the area being welded. 2.d.5. Do not work next to welding power source. i i

3 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. SAFETY 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. 3.b. Insulate yourself from work and ground using dry insulation. Make certain the insulation is large enough to cover your full area of physical contact with work and ground. In addition to the normal safety precautions, if welding must be performed under electrically hazardous conditions (in damp locations or while wearing wet clothing; on metal structures such as floors, gratings or scaffolds; when in cramped positions such as sitting, kneeling or lying, if there is a high risk of unavoidable or accidental contact with the workpiece or ground) use the following equipment: Semiautomatic DC Constant Voltage (Wire) Welder. DC Manual (Stick) Welder. AC Welder with Reduced Voltage Control. 3.c. In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head, nozzle or semiautomatic welding gun are also electrically hot. 3.d. Always be sure the work cable makes a good electrical connection with the metal being welded. The connection should be as close as possible to the area being welded. 3.e. Ground the work or metal to be welded to a good electrical (earth) ground. 3.f. Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe operating condition. Replace damaged insulation. 3.g. Never dip the electrode in water for cooling. 3.h. Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders. 3.i. When working above floor level, use a safety belt to protect yourself from a fall should you get a shock. 3.j. Also see Items 6.c. and 8. 4.b. Use suitable clothing made from durable flame-resistant material to protect your skin and that of your helpers from the arc rays. 4.c. Protect other nearby personnel with suitable, non-flammable screening and/or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal. FUMES AND GASES can be dangerous. 5.a. Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases. When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to keep fumes and gases away from the breathing zone. When welding with electrodes which require special ventilation such as stainless or hard facing (see instructions on container or MSDS) or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes, keep exposure as low as possible and within applicable OSHA PEL and ACGIH TLV limits using local exhaust or mechanical ventilation. In confined spaces or in some circumstances, outdoors, a respirator may be required. Additional precautions are also required when welding on galvanized steel. 5. b. The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment, maintenance of the equipment and the specific welding procedure and application involved. Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits. 5.c. Do not weld in locations near chlorinated hydrocarbon 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 material safety data sheet (MSDS) and follow your employer s safety practices. MSDS forms are available from your welding distributor or from the manufacturer. 5.f. Also see item 1.b. ii ii

4 WELDING and CUTTING SPARKS can cause fire or explosion. 6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available. 6.b. Where compressed gases are to be used at the job site, special precautions should be used to prevent hazardous situations. Refer to Safety in Welding and Cutting (ANSI Standard Z49.1) and the operating information for the equipment being used. 6.c. When not welding, make certain no part of the electrode circuit is touching the work or ground. Accidental contact can cause overheating and create a fire hazard. 6.d. Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside. They can cause an explosion even though they have been cleaned. For information, purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances, AWS F4.1 from the American Welding Society (see address above). 6.e. Vent hollow castings or containers before heating, cutting or welding. They may explode. 6.f. Sparks and spatter are thrown from the welding arc. Wear oil free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes and a cap over your hair. Wear ear plugs when welding out of position or in confined places. Always wear safety glasses with side shields when in a welding area. 6.g. Connect the work cable to the work as close to the welding area as practical. Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains, crane cables or other alternate circuits. This can create fire hazards or overheat lifting chains or cables until they fail. 6.h. Also see item 1.c. 6.I. Read and follow NFPA 51B Standard for Fire Prevention During Welding, Cutting and Other Hot Work, available from NFPA, 1 Batterymarch Park, PO box 9101, Quincy, Ma SAFETY 7.b. 7.c. 7.d. 7.e. 7.f. 7.g. CYLINDER may explode if damaged. 7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used. All hoses, fittings, etc. should be suitable for the application and maintained in good condition. Always keep cylinders in an upright position securely chained to an undercarriage or fixed support. 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. Never allow the electrode, electrode holder or any other electrically hot parts to touch a cylinder. Keep your head and face away from the cylinder valve outlet when opening the cylinder valve. Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use. Read and follow the instructions on compressed gas cylinders, associated equipment, and CGA publication P-l, Precautions for Safe Handling of Compressed Gases in Cylinders, available from the Compressed Gas Association 1235 Jefferson Davis Highway, Arlington, VA FOR ELECTRICALLY powered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer s recommendations. 8.c. Ground the equipment in accordance with the U.S. National Electrical Code and the manufacturer s recommendations. 6.j. Do not use a welding power source for pipe thawing. Refer to for additional safety information. iii iii

5 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes: SAFETY 5. Toujours porter des lunettes de sécurité dans la zone de soudage. Utiliser des lunettes avec écrans lateraux dans les zones où l on pique le laitier. 6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque d incendie dû aux étincelles. Sûreté Pour Soudage A L Arc 1. Protegez-vous contre la secousse électrique: a. Les circuits à l électrode et à la piéce sont sous tension quand la machine à souder est en marche. Eviter toujours tout contact entre les parties sous tension et la peau nue ou les vétements mouillés. Porter des gants secs et sans trous pour isoler les mains. b. Faire trés attention de bien s isoler de la masse quand on soude dans des endroits humides, ou sur un plancher metallique ou des grilles metalliques, principalement dans les positions assis ou couché pour lesquelles une grande partie du corps peut être en contact avec la masse. c. Maintenir le porte-électrode, la pince de masse, le câble de soudage et la machine à souder en bon et sûr état defonctionnement. d.ne jamais plonger le porte-électrode dans l eau pour le refroidir. e. Ne jamais toucher simultanément les parties sous tension des porte-électrodes connectés à deux machines à souder parce que la tension entre les deux pinces peut être le total de la tension à vide des deux machines. f. Si on utilise la machine à souder comme une source de courant pour soudage semi-automatique, ces precautions pour le porte-électrode s applicuent aussi au pistolet de soudage. 2. Dans le cas de travail au dessus du niveau du sol, se protéger contre les chutes dans le cas ou on recoit un choc. Ne jamais enrouler le câble-électrode autour de n importe quelle partie du corps. 3. Un coup d arc peut être plus sévère qu un coup de soliel, donc: a. Utiliser un bon masque avec un verre filtrant approprié ainsi qu un verre blanc afin de se protéger les yeux du rayonnement de l arc et des projections quand on soude ou quand on regarde l arc. b. Porter des vêtements convenables afin de protéger la peau de soudeur et des aides contre le rayonnement de l arc. c. Protéger l autre personnel travaillant à proximité au soudage à l aide d écrans appropriés et non-inflammables. 4. Des gouttes de laitier en fusion sont émises de l arc de soudage. Se protéger avec des vêtements de protection libres de l huile, tels que les gants en cuir, chemise épaisse, pantalons sans revers, et chaussures montantes. 7. Quand on ne soude pas, poser la pince à une endroit isolé de la masse. Un court-circuit accidental peut provoquer un échauffement et un risque d incendie. 8. S assurer que la masse est connectée le plus prés possible de la zone de travail qu il est pratique de le faire. Si on place la masse sur la charpente de la construction ou d autres endroits éloignés de la zone de travail, on augmente le risque de voir passer le courant de soudage par les chaines de levage, câbles de grue, ou autres circuits. Cela peut provoquer des risques d incendie ou d echauffement des chaines et des câbles jusqu à ce qu ils se rompent. 9. Assurer une ventilation suffisante dans la zone de soudage. Ceci est particuliérement important pour le soudage de tôles galvanisées plombées, ou cadmiées ou tout autre métal qui produit des fumeés toxiques. 10. Ne pas souder en présence de vapeurs de chlore provenant d opérations de dégraissage, nettoyage ou pistolage. La chaleur ou les rayons de l arc peuvent réagir avec les vapeurs du solvant pour produire du phosgéne (gas fortement toxique) ou autres produits irritants. 11. Pour obtenir de plus amples renseignements sur la sûreté, voir le code Code for safety in welding and cutting CSA Standard W PRÉCAUTIONS DE SÛRETÉ POUR LES MACHINES À SOUDER À TRANSFORMATEUR ET À REDRESSEUR 1. Relier à la terre le chassis du poste conformement au code de l électricité et aux recommendations du fabricant. Le dispositif de montage ou la piece à souder doit être branché à une bonne mise à la terre. 2. Autant que possible, I installation et l entretien du poste seront effectués par un électricien qualifié. 3. Avant de faires des travaux à l interieur de poste, la debrancher à l interrupteur à la boite de fusibles. 4. Garder tous les couvercles et dispositifs de sûreté à leur place. iv iv

6 Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product as much pride as we have in bringing this product to you! 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 Please refer to for any updated information. The material in this document is for information only and is subject to change without notice. While reasonable efforts have been made in the preparation of this document to assure its accuracy, The Lincoln Electric Co. assumes no liability resulting from errors or omissions in this document, or from the use of the information contained herein. The Lincoln Electric Co. reserves the right to make changes in the product design without reservation and without notification to its users. Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received. Please record your equipment identification information below for future reference. This information can be found on your machine nameplate. Product Model Number Code Number or Date Code Serial Number Date Purchased Where Purchased Whenever you request replacement parts or information on this equipment, always supply the information you have recorded above. The code number is especially important when identifying the correct replacement parts. On-Line Product Registration - Register your machine with Lincoln Electric either via fax or over the Internet. For faxing: Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it. For On-Line Registration: Go to our WEB SITE at Choose Quick Links and then Product Registration. Please complete the form and submit your registration. Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection. The level of seriousness to be applied to each is explained below: WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life. CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment. v v

7 NOTES vi vi

8 Chapter 1, Product Overview TABLE OF CONTENTS Specifications Product Summary General Physical Description Recommended Processes and Equipment Recommended Processes Process Limitations Equipment Limitations Recommended Power Sources Design Features Arc Performance User Controls Wire Drive and Frame Chapter 2, Initial Setup Accessories Included with the Nomenclature Nomenclature Continued Tools Needed Assembly Preparation Chapter 3, Assembly Right-Hand Horizontal Fillet Welds Right-Hand Butt and Groove Welds Flat Fillet Chapter 4, Wheel Configurations Track Guided Welding Self-Guided, Four-Wheeled Welding Manually Steered, Three-Wheeled Welding Joint Guide Wheels Chapter 5, Wire Guides and Drive Roll Removal and Installation Wire Guides and Drive Roll Removal and Installation Chapter 6, Wire Straightener Adjustment Wire Straightener Adjustment Chapter 7, Leveling Leveling Chapter 8, Alternate Configurations Feed Plate Positions Wire Reel Spindle Positions Flux Hopper Mounting Options Slide Positions TOC-1 TOC-1

9 TABLE OF CONTENTS Chapter 9, Cables and Connections System Setup Wire Drive Connection Controller and Power Source Connectors ArcLink Control Cables Weld Cable Sizes Connecting Welding Power Cables to Contact Nozzle Assembly - All Configurations Loading Electrode Loading a Coil on to a Reel Chapter 10, Operation Safety Precautions Pendant Controls Making a Weld Constant Current Constant Voltage Weld Sequence Start Options End Options Restrike Timer Weld Mode Searching Memories Recalling a Memory with Memory Buttons Saving a Memory with Memory Buttons Limits Setting Limits Enabling/Disabling Limits Setup Features Menu Accessing the Setup Menu User Defined Parameters Touch Sense Moving the Driving the Without Welding Chapter 11, Troubleshooting and Maintenance Troubleshooting Maintenance Chapter 12, Software Installation Connecting the to a Computer Updating Software Chapter 13, Kits and Accessories Optional Kits and Accessories Drive Roll and Guide Tube Kits Chapter 14, Diagram Machine Wiring Diagram Parts List... P-571 TOC-2 TOC-2

10 Specifications PRODUCT OVERVIEW VOLTAGE Specifications INPUT AMPERES 40 VDC 8 A DUTY CYCLE* Rated Output at F (40 0 C) AMPERES 100% 1000 A Note: *Duty Cycle is based upon the amount of welding performed in a 10 minute period. Physical Dimensions (Overall Size and Weight Dependent Upon Configuration) MODEL HEIGHT WIDTH DEPTH WEIGHT (as shipped) K Inches 23 Inches 36 Inches 179 Lbs. (736mm) (548mm) (914mm) (81 kg) OPERATING TEMPERATURE Temperature Ranges STORAGE TEMPERATURE -40 to F -40 to F (-40 to 50 0 C) (-40 to 85 0 C) SAW GEARING WFS Range Wire Sizes 57:1 95:1 142:1 (Factory Installed Gearing) 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) 1/16 to 5/64 inch (1.6 to 2.4 mm) 1/16 to 3/32 inch (1.6 to 2.4 mm) 1/16 to 7/32 inch (1.6 to 5.6 mm) Travel Speed Range 10 to 100 ipm (0.25 to 2.5 m/min)

11 Product Summary General Physical Description PRODUCT OVERVIEW The Cruiser tractor is a self-propelled carriage for performing subarc welds, specifically designed to improve productivity. The Cruiser tractor features a patent pending mast and arm structure for fast setup. Heat-treated aluminum alloy tubing is used for the mast and arm resulting in a rigid frame that keeps the wire drive in a steady position. The main components are: wire drive, spool spindle and flux hopper. Grooves in the tubing align with a key in the clamp to let the clamp slide along the length of the tubing without rotating. Other clamps do not have the key and rotate as well as slide on the tubing. Wire is fed to the arc with a wire drive based on the proven PF-10S. All of the drive rolls, nozzles and contact tips from the PF-10S may be assembled to the Cruiser tractor. A new low-friction wire straightener reliably straightens the wire. 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 stickout and position of the wire in the joint. The entire mast and arm structure separates from the base for portability and mobility purposes. Driving the Cruiser tractor is a permanent magnet direct current (DC) motor with all metal gears. The motor transfers power to the axle through a worm drive for smooth transmission. A tachometer keeps the Cruiser tractor speed consistent. The wheels are made from reinforced aluminum oxide and withstand high heat, abrasive flux and impact. A gear and wheels are mounted on the axle for operating on K396 track sections. The front wheels of the Cruiser tractor may be configured for three- or four-wheel operation. The flexible wheel configuration lets the Cruiser tractor be assembled in a manner for the best balance while aligning the wheels for the best tracking of the joint. All of the controls are housed in a light-weight pendant that connects with a cable to the Cruiser tractor. The pendant housing is fabricated from aluminum to resist impacts and high temperatures

12 PRODUCT OVERVIEW Recommended Processes and Equipment Recommended Processes SAW (alternating current [AC], DC+ and DC-) up to 1,000 amps Tiny Twin. Process Limitations The Cruiser tractor does not support open arc procedures. The Cruiser tractor only supports one arc. Equipment Limitations Because of cable inductance, do not use more than 100 feet (30 m) of electrode and 100 feet (30 m) of work cable. For robust digital communications, do not use more than 200 feet (60 m) of control cable. The Cruiser tractor operates on 40 volts direct current (VDC) only. There is no 115 volts alternating current (VAC) in the Cruiser tractor. The flux hopper holds a maximum of 15 lbs (6.8 kg) of flux. Recommended Power Sources Power Wave AC/DC

13 Design Features PRODUCT OVERVIEW Arc Performance The Cruiser tractor and Power Wave AC/DC 1000 combination brings high productivity to field welding. User Controls Light weight, hand-held pendant Four memories for quick selection of common procedures Full sequence control for tailoring the weld from start to end All welding controls located at the pendant including program selection. 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 Compatible with standard Lincoln Electric submerged-arc contact nozzles. and Frame Three- or four-wheel patent-pending design for the best tracking and balancing Permanent magnet DC motor with tachometer for steady, accurate travel speeds Metal gears for long life Easily engaged travel clutch Fully assembled for track use Aluminum-oxide wheels for superior traction and heat resistance Heavy-duty slides for adjusting the electrode position in the joint

14 INITIAL SETUP Accessories Included with the Accessories* Conduit Tubing Flux Tube Retaining Springs (Two) Flux Tube Connectors (Two) Wire Reel Assembly 5/32 Inch Flux Cone Assembly Wheels for Track Operation 5/32 Inch Contact Tip Manual Guided Steering Wheel Contact Nozzle Extension Front and Rear Guide Bars Nozzle Extension Insulator Butt/Fillet/Lap Joint Tracker Flux Tubing (Three) Note: *The Lincoln Electric Cruiser tractor does not include a control cable

15 INITIAL SETUP Nomenclature Flux Hopper Lift Bail Mast Tube Clamp Handle Spindle Brake Vertical Slide Wire Drive Clamp Wire Straightener Adjustment Arm Reel Holder Reel Heat Shields Voltage Sense Lead (67) Steering Knob Wire Drive Steering Knob Locking Nut Front Wheel and Clamp Assembly, Left Bar Wire Straightener Idle Arm Drive Roll Front Tubes Wheel Scraper Flux Hopper Feedplate Brackets Contact Nozzle Electrode Cable Connection Front Guide Wheel Outgoing Drive Tube Feedplate Locking Screw Front Guide Bar Figure 2-1 Nomenclature

16 INITIAL SETUP Nomenclature Continued Manual Steering Wheel Collar Wire Guide Anchor Horizontal Slide Flux Valve Slide Bracket Slide Tube Clamp Clutch Electrode Cable Strain Relief Rear Guide Bar Controller Bracket Control Cables Strain Relief Rear Guide Wheel Figure 2-2 Nomenclature Continued

17 Tools Needed INITIAL SETUP To set up the Cruiser tractor, the following tools are needed. 7/16-inch (Preferred) or 11 mm Combination Wrench 1/2-inch (Preferred) or 13 mm Combination Wrench 5/16-inch (Preferred) or 8 mm Allen Wrench 9/16-inch (Preferred) or 15 mm Combination Wrench 1-inch (Preferred) or 25 mm Combination Wrench 1/4-inch (Preferred) or 6 mm Allen Wrench

18 Assembly Preparation INITIAL SETUP Before configuring the Cruiser tractor for welding, parts must be removed from their shipped positions. The following steps configure the Cruiser tractor to be put in various welding configurations. Depending on the joint to be welded, some parts will not be used. 1. Remove the conduit anchor using a 7/16-inch (11 mm) wrench. Set aside. 2. Loosen (two) clamp screws using a 1/2-inch (13 mm) wrench and remove the joint tracking wheel assembly. Set aside

19 INITIAL SETUP 3. Remove wire reel mounting spindle and bracket. Loosen (two) clamp screws using a 1/2-inch (13 mm) wrench and slide wire reel mounting spindle and bracket off the long support tube. Set aside. 4. Remove the flux hopper assembly. Loosen (two) clamp screws using a 1/2- inch (13 mm) wrench and slide flux hopper assembly off the long support arm. Set aside. 5. Remove manual steering wheel assembly. Loosen (two) clamp screws using a 1/2-inch (13 mm) wrench and slide the assembly off the long support tube. Set aside. The Cruiser tractor is now ready to be assembled for welding. See Chapter 3, Assembly

20 Assembly ASSEMBLY Before the Cruiser tractor can be set up for welding, all steps in Assembly Preparation on page 2-5 must be completed. Right-Hand Horizontal Fillet Welds Figure 3-1 The Configured for Track Guided Right-Hand Horizontal Fillet Welds

21 ASSEMBLY 1. Loosen wire drive mounting bracket from horizontal slide by loosening four nuts using a 1/2-inch (13 mm) wrench. Relocate the wire drive bracket located almost in the center of the horizontal slide. 2. Turn the crank as shown to locate the wire drive mounting bracket in the center of the horizontal slide. Tighten the four nuts. 3. Loosen the feedplate locking screw using a 5/16 inch (8 mm) Allen wrench. Rotate the feedplate counterclockwise to 45. Tighten the feedplate locking screw

22 ASSEMBLY 4. Mount the flux hopper to the feedplate with long carriage bolts using a 7/16- inch (11 mm) wrench. 5. Install one flux tube retaining ring

23 ASSEMBLY 6. Install the contact nozzle extension. 7. Install second flux tube retaining ring. 8. Install the flux cone assembly and tighten by turning the thumb screw clockwise

24 ASSEMBLY 9. Install the flux delivery tube from the flux hopper to the flux cone or to the end of the contact nozzle assembly using the (two) flux tube securing rings. 10. Install wire reel spindle support assembly, so spindle faces towards the left and points horizontally or slightly upwards. Tighten clamp screws using a 1/2-inch (13 mm) wrench. 11. Remount the conduit anchor to the end of the long support using a 7/16- inch (11 mm) wrench. 12. Install the conduit by cutting to the appropriate length, so one end fits into the inlet of the wire straightener, and the other end fits into the conduit anchor. CAUTION Do not weld without this tube installed!

25 ASSEMBLY 13. Mount control pendant in the pendant holder. Continue to Chapter 4, Wheel Configurations

26 ASSEMBLY Right-Hand Butt and Groove Welds Figure 3-2 The Configured for Right-Hand Track Guided Butt Welds 1. Loosen wire drive mounting bracket from horizontal cross slide by loosening four nuts using a 1/2-inch (13 mm) wrench. 2. Raise the wire drive using the vertical slide crank until the contact nozzle clears the front support tube. 1/2 / 13mm

27 ASSEMBLY 3. Loosen the feedplate locking screw using a 5/16-inch (8 mm) Allen wrench. 4. Rotate feedplate, so the contact nozzle assembly is completely clear of the front support tube Tighten the feedplate locking screw using a 5/16-inch (8 mm) Allen wrench

28 ASSEMBLY 6. Slide wire drive mounting bracket toward the right-hand end of the horizontal slide about 1/2 inch (13 mm) from end. If more reach to weld seam is desired, loosen the cross slide clamp and slide to the right, or loosen the horizontal cross seam tube clamp and slide the tube to the right using a 1/2-inch (13 mm) wrench. 1/2 /13mm 7. Tighten the wire drive bracket mounting screws with four nuts using a 1/2-inch (13 mm) wrench. 8. Install the contact tip to the contact nozzle. Install the flux cone assembly to the contact tip

29 ASSEMBLY 9. Secure flux cone assembly with the thumbscrew. 10. Slide crossslide assembly to the end of horizontal tube. 11. Tighten the vertical slide bracket mounting screws using a 1/2-inch (13 mm) wrench

30 ASSEMBLY 12. Rotate feedplate clockwise until contact nozzle assembly is perpendicular with welding surface. 13. Loosen wire reel mounting arm by loosening two nuts using a 1/2-inch (13 mm) wrench. Slide wire reel mounting arm as far as possible. 14. Tighten wire reel mounting arm by tightening two nuts using a 1/2-inch (13 mm) wrench

31 ASSEMBLY 15. Remove the flux hopper from its mounting plate and clamp assembly with two long carriage bolts using a 7/16-inch (11 mm) wrench. 16. Mount the flux hopper using flux hopper/drive roll faceplate brackets and long carriage bolts. Secure with two nuts using a 7/16-inch (11 mm) wrench. 17. Attach the flux hose to the flux hopper and nozzle assembly

32 ASSEMBLY 18. Remount the electrode reel and mounting bracket on the long support arm, so the spindle is centered approximately 9 inches (225 mm) from the long support arm clamp bracket and facing the right-hand side. The spindle should be horizontally positioned. Tighten two clamp screws using a 1/2-inch (13 mm) wrench. 9.5 / 240mm 19. Remount the conduit anchor to the end of the long support using a 7/16- inch (11 mm) wrench. 20. Install the conduit by cutting to the appropriate length, so one end fits into the inlet of the wire straightener, and the other end fits into the conduit anchor. CAUTION Do not weld without this tube installed!

33 ASSEMBLY 21. Mount control pendant to the bracket on flux hopper. Continue to Chapter 4, Wheel Configurations

34 Flat Fillet ASSEMBLY 1. Remove the long horizontal tube by loosening clamp nuts using a 1/2-inch (13 mm) wrench and sliding it from its clamp bracket. Figure 3-3 Flat Fillet 2. Remove front outrigger bar assembly by removing two screws using a 7/16- inch (11 mm) wrench

35 ASSEMBLY 3. Disconnect sense lead (67) and motor control lead from the Cruiser tractor chassis. 4. Remove the wire drive assembly from the wire drive mounting clip using a 5/16-inch (8 mm) Allen wrench on the right side and 9/16- inch (15 mm) wrench on left side. Set aside. 5. Loosen the head mounting and slide the assembly clamp by loosening clamp screws using a 1/2-inch (13 mm) wrench from the horizontal cross support tube. Remove slide assembly and set aside

36 ASSEMBLY 6. Move horizontal cross support tube by loosening its clamp and sliding to the left until the tube is about equally spaced on both sides of the mast. Tighten the clamp. Note: This may require some minor adjustment later. 7. Block the Cruiser tractor to slightly elevate front wheel assemblies and front wheel support tubes. 8. Loosen both front wheel assembly clamp brackets with two machine screws using a 1/2-inch (13 mm) wrench and slide both assemblies from support tubes

37 ASSEMBLY 9. Install the flanged wheel assembly on the left-hand tube with the wheel facing right. Ensure the wheel side wall is perpendicular. Tighten the wheel assembly clamp located inside of the wheel bracket about 3 inches (75 mm) from the front edge of the tube clamp bracket. 10. Relocate the slide tube clamp and collar using a 1/2-inch (13 mm) wrench and 1/4-inch (6 mm) Allen wrench. Move down the mast until the bottom of the collar is about 4 inches (100 mm) above the Cruiser tractor base. 4 /100mm 11. Rotate the long horizontal tube 90. Assemble the long horizontal tube

38 ASSEMBLY 12. Remount the slide assembly to the right-hand side of the long support tube as close to the long tube clamp bracket as possible. Adjust mounting to ensure the vertical slide is vertical. Tighten. Note: The horizontal slide handle is still on the right-hand end of the slide. 13. Remove the motor/gearbox mounting bracket from the horizontal cross slide by removing four nuts using a 7/16-inch (11 mm) wrench. 14. Invert the bracket, so the motor/gearbox clamp flange is now at the bottom and remount with the horizontal center of the bracket located about on the centerline of the vertical adjuster. Tighten. 15. Remount the motor and gearbox using the machine screws removed earlier using a 7/16-inch (11 mm) wrench

39 ASSEMBLY 16. Rotate the drive roll faceplate approximately 45 clockwise by loosening the faceplate locking screw using a 5/16-inch (8 mm) Allen wrench. Check that the angle of the nozzle assembly is at 45 from the horizontal and tighten the drive roll faceplate locking screw. 17. Mount the front geared wheel assembly to the left-hand end of the short horizontal cross tube. Ensure that the side-face of the wheel is facing downward and parallel to the Cruiser tractor s surface. Once mounted, tighten two bolts using a 1/2-inch (13 mm) wrench. This wheel will now act as a third guide and support wheel when the Cruiser tractor is set in a 45 trough. 18. Remount the front outrigger bar with two machine screws using a 7/16- inch (11 mm) wrench, so the guidewheel faces upward and extends to the left. Do not tighten at this time as the extension to the left still needs to be set

40 ASSEMBLY 19. Remove rear outrigger bar and reverse it, so it is oriented the same as the front outrigger bar 20. With the Cruiser tractor on a level surface, the two guide wheels on outrigger bars and the traction surface of the fourth wheel mounted to the horizontal cross tube should be aligned, so all track evenly to a plate perpendicular to the Cruiser tractor s surface. 21. Mount the wire reel support assembly to the long tube, so it is pointing upward, and the clamp bracket is toward the rear of the Cruiser tractor located about 9 inches (225 mm) from the right-hand end of the long tube. Tighten the two bolts using a 1/2-inch (13 mm) wrench. 22. Install one flux tube retaining ring

41 ASSEMBLY 23. Install the contact nozzle extension. 24. Install the second flux tube retaining ring. 25. Tighten both outrigger bars. 26. Adjust the rear traction wheel scrapers that are mounted to the rear outrigger bar, so they are 1/4 inch (8 mm) from wheels and tighten scraper bolts

42 ASSEMBLY 28. Remove the flux hopper from its tube clamp bracket. 29. Mount the long bolts using a 7/16- inch (11 mm) wrench to the electrode drive face using the two brackets already installed

43 ASSEMBLY 30. Install the flux delivery tube from the flux hopper to the flux cone or to the end of the contact nozzle assembly using the (two) flux tube securing rings. Note: The flux cone assembly can be used. See page 3-4 step 8 for flux cone installation. 31. Reconnect the sense lead (67) and motor power cable to the Cruiser tractor chassis. 32. Install the control pendant with the control cable under the rear strain relief loop. The control pendant can be stored on the front of the flux hopper when the control pendant is not in use. The Cruiser tractor is now ready to be set into the work positioned at 45 or placed in a suitable fixture

44 WHEEL CONFIGURATIONS Wheel Configurations The Cruiser tractor features a patent-pending design that provides freedom for many different wheel configurations. The wheels and guides can be oriented in the best position for just about any joint. Track Guided Welding The Cruiser tractor comes from the factory assembled for track welding. Figure 4-1 Track Welding 1. Verify the front wheels are perpendicular to the work piece and aligned with the track. 2. Change P.12 wheel size to 5.65 inches in the setup menu. See Accessing the Setup Menu on page

45 WHEEL CONFIGURATIONS Self-Guided, Four-Wheeled Welding Self-guided means the Cruiser tractor is steered slightly towards a wall. Outriggers with guide wheels roll along the wall keeping the Cruiser tractor at a constant distance. The Cruiser tractor comes from the factory assembled for self-guiding on the right-hand side. 1. Verify the front wheels are perpendicular. 2. Left- and right-hand guided: a. Guiding from the Right Side. Loosen the bolts holding the front and rear outriggers using a 7/16-inch (11 mm) wrench. Slide outriggers as needed and then tighten. b. Guiding from the Left Side. Remove bolts holding the front and rear outriggers using a 7/16-inch (11 mm) wrench. Reassemble with outrigger guide wheels on the left side. Position as needed and then tighten

46 WHEEL CONFIGURATIONS 3. Loosen the steering locking nuts. 4. Adjust the steering knob on each wheel to aim the wheel approximately 1 towards the wall. Angling the wheels too much may result in rear guide wheels sliding away from the wall

47 WHEEL CONFIGURATIONS Manually Steered, Three-Wheeled Welding When the Cruiser tractor is assembled for manual steering, the operator adjusts the travel direction with a spring loaded steering bar. 1. Prop up or raise the Cruiser tractor, so the front wheels are off the ground. 2. Remove the front outrigger assembly by removing two bolts using a 7/16-inch (11 mm) wrench. 3. Loosen two clamp bolts using a 1/2-inch (13 mm) wrench on each front steering wheels. Slide the steering wheels off of the tubes

48 WHEEL CONFIGURATIONS 4. Slide the manual steering assembly onto one of the front tubes. Position the wheel, so it is perpendicular to the work piece and tighten the two clamp bolts with a 1/2-inch (13 mm) wrench

49 Joint Guide Wheels WHEEL CONFIGURATIONS The joint guide wheels work best for single pass butt or groove welds with prepared edges. 1. Prop up or raise the Cruiser tractor, so the front wheels are off the ground. 2. Remove the front outrigger assembly by removing two bolts using a 7/16-inch (11 mm) wrench. 3. Loosen two clamp bolts using a 1/2-inch (13 mm) wrench on each front steering wheels. Slide the steering wheels off of the tubes

50 WHEEL CONFIGURATIONS 4. For improved access, remove one of the front tubes by loosening two clamps bolts on the base clamp using a 1/2-inch (13 mm) wrench. 5. Slide the manual steering assembly onto the remaining front tube. Position the wheel, so it is perpendicular to the work piece and tighten two clamp bolts using a 1/2-inch (13 mm) wrench

51 NOTES

52 WIRE GUIDES & DRIVE ROLL - REMOVE & INSTALL Wire Guides and Drive Roll Removal and Installation Wire Guides and Drive Roll Removal and Installation 1. Turn off the power at the welding power source. 2. If the flux hopper is mounted to the wire drive, remove one of the bolts holding the flux hopper and swing the flux hopper out of the way. 3. Securely place a pry bar in the wire drive idle arm to relieve idle arm pressure. 4. Using a 1/4-inch hex key, remove two screws holding wire straightener clamps to the wire drive. 5. Remove the wire straightener and wire guide. 6. Using a 1/4-inch hex key, remove two screws holding the contact nozzle to the wire drive. 7. Remove the contact nozzle and guide. 8. Using a 1-inch (25 mm) wrench, remove the nut and washer holding the drive rolls in place. Remove the drive rolls

53 WIRE GUIDES & DRIVE ROLL - REMOVE & INSTALL 9. Obtain new drive roll kit. Note: The drive comes as two halves. 10. Install the drive rolls, washer and hex nut. 11. Remove the pry bar relieving the idle arm pressure. 12. Place the outlet guide in the contact nozzle and install the contact nozzle to the wire drive. Tighten the contact nozzle clamp screws with a 1/4-inch hex key. 13. Assemble the inlet guide and wire straightener. Tighten wire straightener clamp screws with a 1/4-inch hex key. 14. Insert wire through the wire straightener and into the wire drive. 15. Turn power on at the welding power source. WARNING ELECTRIC SHOCK CAN KILL THE WIRE, WIRE DRIVE, REEL AND CONTACT NOZZLE WILL BE ELECTRI- CALLY HOT DURING INCHING IF TOUCH SENSING IS ENABLED Inch the wire forward until the wire is between the drive roll and idler roll. 17. Adjust the idle arm pressure with a 9/16-inch (15 mm) wrench

54 WIRE STRAIGHTENER ADJUSTMENT Wire Straightener Adjustment WARNING ELECTRIC SHOCK CAN KILL TURN THE INPUT POWER OFF AT THE DISCONNECT SWITCH BEFORE WORKING ON THIS EQUIPMENT. DO NOT TOUCH ELECTRICALLY HOT PARTS. ONLY QUALIFIED PERSONNEL SHOULD INSTALL, USE OR SERVICE THIS EQUIPMENT. DO NOT ADJUST THE WIRE STRAIGHTENER WHILE WELDING The wire straightener is used to control the amount of cast (curve) in the wire. Excessive cast may effect alignment of the wire in the joint. Too little cast may result in insufficient wire contact in the contact tip

55 WIRE STRAIGHTENER ADJUSTMENT 1. Turn off power at the welding power source. 2. Using a 1/4-inch hex key, loosen two screws holding the wire straightener clamps to the wire drive. 3. Rotate the wire straightener to add or remove cast from the wire. 4. Tighten the screws holding the wire straightener to the wire drive. 5. Turn on the power at the welding power source. 6. Inch the wire through the wire drive. Adjust the amount of pressure on the wire until the desired cast is achieved when the wire exits the contact tip. Remove Cast Add Cast Figure 6-1 Wire Straightener Cast

56 Leveling LEVELING When configured with four wheels, it may be necessary to make adjustments to the front wheels to keep the Cruiser tractor level. Leveling 1. Loosen the clamp at the Cruiser tractor base by loosening two bolts using a 1/2-inch (13 mm) wrench. 2. Rotate the front tube counterclockwise

57 LEVELING 3. Tighten the clamp. 4. Loosen the wheel clamp. 5. Rotate the wheel assembly clockwise

58 LEVELING 6. Use a square for final alignment. 7. Tighten the clamp

59 NOTES

60 ALTERNATE CONFIGURATIONS Alternate Configurations The Cruiser tractor components may be assembled in countless ways. This chapter illustrates a few of the many possibilities. Feed Plate Positions The centerline of the wire through the wire drive is not symmetric. If the feed plate is rotated 180, it results in a different centerline for the wire. Moving the centerline may be helpful in configurations where access to the contact nozzle is limited. When changing the feeding direction, also change P.19 default Forward direction. See Setup Features Menu on page Factory Assembled Configuration, A-B, Idle Arm on Top Alternate Configuration, B-A, Idle Arm on Bottom Figure 8-1 Feed Plate Positions

61 ALTERNATE CONFIGURATIONS 1. Turn off the power at the welding power supply. 2. Loosen the feedplate locking screw using a 5/16-inch (8 mm) Allen wrench. 3. Rotate the feedplate to the new position. Do not allow surfaces at electrode potential to touch the frame, flux hopper, base or slides of the Cruiser tractor. 4. Tighten the feedplate locking screw using a 5/16-inch (8 mm) Allen wrench

62 ALTERNATE CONFIGURATIONS 5. The Cruiser tractor is equipped from the factory with A as the inlet and B as the outlet. To make B the inlet and A the outlet, see the Setup Features Menu on page

63 ALTERNATE CONFIGURATIONS Wire Reel Spindle Positions WARNING ELECTRIC SHOCK CAN KILL TURN THE INPUT POWER OFF AT THE DISCONNECT SWITCH BEFORE WORKING ON THIS EQUIPMENT. DO NOT TOUCH ELECTRICALLY HOT PARTS. DO ALLOW THE WIRE SPOOL OR WIRE TO TOUCH THE CRUISER TRACTOR FRAME, CROSS SLIDES, BASE OR FLUX HOPPER. ONLY QUALIFIED PERSONNEL SHOULD INSTALL, USE OR SERVICE THIS EQUIPMENT. FAILURE TO PROPERLY SECURE THE WIRE REEL SPINDLE OR TO BALANCE THE CRUISER TRACTOR MAY RESULT IN PHYSICAL INJURY. DO NOT ORIENT THE SPINDLE DOWN. THE CRUISER TRACTOR MUST REMAIN STABLE AND BALANCED BOTH WHEN NO COIL IS PRESENT AND WITH FULLY LOADED COIL(S) Figure 8-2 Do Not Orient the Wire Reel Spindle Downwards The spindle may be clamped to any of the tubes. Always ensure the spindle is pointing horizontal or upwards. Never aim the spindle in a down direction

64 ALTERNATE CONFIGURATIONS Flux Hopper Mounting Options The flux hopper may be mounted in several positions on the Cruiser tractor. The best location for the flux hopper will keep the flux tube as vertical as much as possible. WARNING TO PREVENT PHYSICAL INJURY, THE CRUISER TRACTOR MUST REMAIN STABLE AND BALANCED BOTH WHEN THE FLUX HOPPER IS FULL AND EMPTY Figure 8-3 Flux Hopper Mounted to the Wire Drive

65 ALTERNATE CONFIGURATIONS Figure 8-4 Flux Hopper Mounted to Mast Vertically Figure 8-5 Flux Hopper Mounted to Mast Horizontally For the best flux flow, mount the hopper in a position, so the flux tube is as vertical as possible

66 ALTERNATE CONFIGURATIONS Good Flow Poor Flow Figure 8-6 Flux Tube Position

67 ALTERNATE CONFIGURATIONS Slide Positions As assembled from the factory, slides are oriented horizontal and vertical. For some fillet and lap joints, it may be desirable to mount the slides on a diagonal axis. One slide controls electrode stickout, and the other slide controls position of the wire in the joint. Slides on Horizontal and Vertical Axis Slides on Diagonal Axes Figure 8-7 Slide Positions

68 CABLES AND CONNECTIONS Cables and Connections System Setup K2683-xx Heavy Duty Arclink Cable K Pendant Electrode Cable Work Cable K1811-xx Work Sense Lead (mount as close as possible to the Cruiser tractor) Figure 9-1 System Setup 1 K Cruiser TM Tractor 3 K Work Sense Lead 4 K Pendant (Included with K Cruiser TM 5 K2344-xx Power Wave AC/DC K2683-xx Digital Control Cable Weld Power Cables: 0 to 250 ft. at 80% Duty Cycle (Two) 7 K Weld Power Cable - Lug to Lug (4/0) - 35 ft. 8 K Weld Power Cable - Lug to Lug (4/0) - 60 ft. 9 K Weld Power Cable - Lug to Lug (4/0, 600 A, 60% ) ft. Weld Power Cables: 0 to 250 ft. at 100% Duty Cycle (Three) 10 K Weld Power Cable - Lug to Lug (3/0, 600 A, 60% ) - 10 ft. 11 K Weld Power Cable - Lug to Lug (3/0, 600 A, 60% ) - 35 ft. 12 K Weld Power Cable - Lug to Lug (3/0, 600 A, 60% ) - 60 ft

69 CABLES AND CONNECTIONS Wire Drive Connection D E C B A Wire Drive Connector Pin Definition A Motor Power B Motor Power C +5 VDC D Tachometer E Common Figure 9-2 Wire Drive Connection

70 CABLES AND CONNECTIONS Controller and Power Source Connectors D E A C B D E A C B Controller Connector Pin Definition A Arc Link Can B Arc Link Can C 67 Electrode Sense D +40 VDC E Common Power Source Connector Pin Definition A Arc Link Can B Arc Link Can C 67 Electrode Sense D +40 VDC E Common Figure 9-1 Controller and Power Source Connectors

71 CABLES AND CONNECTIONS ArcLink Control Cables ArcLink control cables are available in two forms: K1543-xx series for most indoor or factory installations K2683-xx series for outdoor use or when the equipment is frequently moved. ArcLink/LincNet control cables are special high quality cables for digital communication. The cables are copper 5 conductor cable in a SO-type rubber jacket. There is one 20- gauge twisted pair for network communications. This pair has an impedance of approximately 120 ohms and a propagation delay per foot of less than 2.1 nanoseconds. There are two 12-gauge conductors that are used to supply 40 VDC to the network. The fifth wire is 18 gauge and is used as an electrode sense lead. Note: Use of nonstandard cables may lead to system shutdowns, poor arc starting and wire feeding problems. Control cables connect the power source to the Cruiser tractor and the Cruiser tractor to the pendant. Control cables may be connected end to end to extend their length. Use a maximum of 200 feet (61 m) of control cable between components. ArcLink control cables have the same pin definitions as the pendant connection shown in Wire Drive Connection on page

72 CABLES AND CONNECTIONS Weld Cable Sizes The recommended copper cable sizes for different currents and duty cycles are shown in the following table. Lengths specified are the distance from the welder to the work and back to the welder again. Cable sizes are increased for greater lengths primarily to minimize cable voltage drop. Recommended Cable Sizes (Rubber Covered Copper - Rated 75 0 C)* Amperes Percent Duty Cycle Cable Sizes for Combined Lengths of Electrode and Work Cables 0-50 ft ft ft ft ft /0 3/0 3/0 4/0 2-3/ /0 2-1/0 2-1/0 2-2/0 2-3/ /0 2-1/0 2-1/0 2-2/0 2-3/ /0 2-1/- 2-2/0 2-2/0 2-3/ /0 2-1/0 2-1/0 2-2/0 2-3/ /0 2-2/0 2-2/0 2-3/0 2-4/ /0 3-1/0 3-1/0 2-3/0 2-4/ /0 2-3/0 2-3/0 2-4/0 2-4/0 1, /0 2-4/0 2-4/0 3-3/0 4-2/0 1, /0 3-3/0 3-3/0 3-3/0 3-3/0 1, /0 3-4/0 3-4/0 3-4/0 3-4/0 1, /0 4-4/0 4-4/0 4-4/0 4-4/0 1, /0 4-4/0 4-4/0 4-4/0 4-4/0 1, /0 5-4/0 5-4/0 5-4/0 5-4/0 Note: * Tabled values are for operation at ambient temperatures of 40 C and below. Applications above 40 C may require cables larger than recommended or cables rated higher than 75 C

73 CABLES AND CONNECTIONS Connecting Welding Power Cables to Contact Nozzle Assembly - All Configurations 1. Rotate the brass bar on the nozzle towards the base of the Cruiser tractor. To rotate, loosen the two screws holding the nozzle clamps. Rotate the nozzle assembly and retighten the two screws. 2. Attach the electrode cable to the nozzle tang using the 1/2-inch bolt supplied: a. Attach flat side against tang. b. Place connection lug of sense lead on top of the cable lug and below the bolt head. c. If a second cable is used, attach it to the underside of the tang. 3. Place the cable (or cables) underneath the strain-relief bracket mounted to the Cruiser tractor. Enough cable length must be left toward the front of the Cruiser tractor to permit attaching to the K-231 contact nozzle assembly. Note: Enough slack must also be provided, so adjusting the welding torch to the desired position is not interfered

74 CABLES AND CONNECTIONS 4. Tighten the strain-relief clamp using a 7/16-inch (11 mm) wrench. Note: It might be desirable to leave this clamp loose at this time, but ensure it is tightened before operating the Cruiser tractor, so the cable drag is taken by the Cruiser tractor and not the contact nozzle connection. 5. Verify the electrode sense lead is connected. Note: Appropriate electrode extension and final electrode alignment to the joint may be set by using both cross-slide adjustments. If for some reason the electrode contact nozzle is not perpendicular to the weld seam, it may be adjusted by slightly rotating the drive roll faceplate

75 CABLES AND CONNECTIONS Loading Electrode Loading a Coil on to a Reel 1. Turn the power OFF at the welding power source. 2. Determine the direction the wire will payoff from the spool. 3. Place the coil on the reel. Align cover plate spokes to reel spokes and assemble

76 CABLES AND CONNECTIONS 4. Tighten the spinner nut as much as possible by hand. CAUTION Always ensure the free end of the coil is securely held while the tie wires are being cut and until the wire is fully loaded in the wire drive. Failure to do this may result in a tangled coil Cut and remove only one tie wire holding the free end of the coil. Securely hook the free end of the electrode wire around the reel. 6. Cut and remove the remaining tie wires. 7. Place the coil on the spindle and then place the retaining coil on the spindle. The spring will push out the release bar when it is fully locked

77 NOTES

78 Operation OPERATION Safety Precautions WARNING ELECTRIC SHOCK CAN KILL TURN THE INPUT POWER OFF AT THE DISCONNECT SWITCH BEFORE WORKING ON THIS EQUIPMENT. DO NOT TOUCH ELECTRICALLY HOT PARTS. ONLY QUALIFIED PERSONNEL SHOULD INSTALL, USE OR SERVICE THIS EQUIPMENT. WHEN INCHING WIRE UP AND DOWN, THE ELECTRODE CIRCUIT IS HOT UNLESS TOUCH SENSING IS DISABLED. THE CRUISER TRACTOR MAY CONTINUE WELDING FOR SEVERAL SECONDS AFTER THE STOP BUTTON IS PRESSED. DO NOT ALLOW PARTS AT ELECTRODE POTENTIAL TO TOUCH THE CRUISER TRACTOR FRAME, CROSS SLIDES, BASE, FLUX HOPPER OR OTHER PARTS. DISENGAGING THE CLUTCH DOES NOT STOP THE WELDING ARC. ALWAYS WEAR DRY INSULATING GLOVES

79 OPERATION MECHANICAL HAZARDS CAN CAUSE SERIOUS INJURY DO NOT LEAVE THE CRUISER TRACTOR UNATTENDED WHILE IT IS WELDING OR TRAVELING. THE ELECTRODE REEL, DRIVE ROLLS, WHEELS, GUIDE WHEELS AND WIRE STRAIGHTENER ROLLS TURN DURING WELDING OR INCHING. KEEPS GLOVED HANDS AWAY FROM ROTATING PARTS THAT MAY CATCH THE GLOVE. KEEP AWAY FROM PINCH POINTS. WARNING DO NOT PLACE THE CRUISER TRACTOR ON INCLINED SURFACES WITH THE CLUTCH DISENGAGED. ONLY QUALIFIED PERSONNEL SHOULD INSTALL, USE OR SERVICE THIS EQUIPMENT WARNING ELECTRODE POTENTIAL MAINTAIN CLEARANCE BETWEEN PARTS AT ELECTRODE POTENTIAL AND ALL OTHER CRUISER TRACTOR COMPONENTS. PARTS THAT ARE AT ELECTRODE POTENTIAL ARE: WIRE WIRE SPOOL WIRE STRAIGHTENER ROLLS FOUR SCREW HEADS ON THE BACK OF THE WIRE STRAIGHTER FEED PLATE AND DRIVE ROLLS CONTACT NOZZLE ASSEMBLY

80 OPERATION Four Screw Heads on Back of Wire Straightener Wire and Wire Spool Wire Straightener Feedplate Contact Nozzle Assembly Figure 10-1 Parts with Electrode Potential

81 OPERATION Operate the only on stable and dry surfaces. Operating the on inclined surfaces requires adjusting and/or assembling the tractor differently than shipped from the factory. Do not submerge the. CAUTION It is the responsibility of the user, builder or operator to assemble the to maintain safe electrical clearances and stability. The is rated for outdoor use (IP23) only when the spool is covered The serviceability of a product or structure utilizing any welding programs is and must be the sole responsibility of the builder and/or user. Many variables beyond the control of The Lincoln Electric Company affect the results obtained in applying these programs. These variables include, but are not limited to, the welding procedure, plate chemistry and temperature, weldment design, fabrication methods and service requirements. The available range of a welding program may not be suitable for all applications, and the builder and/or user is and must be solely responsible for the welding program selection

82 OPERATION Pendant Controls WFS LED LED WFS LED WFS AMPS LED AMPERIOS DE LED AMPÈRES DE LED Auto/OFF/Manual Travel Toggle Switch Interrupteur à bascule de voyage d'auto/off/manual Interruptor eléctrico del recorrido de Auto/OFF/Manual Weld Mode Selection Selección de modo de la autógena Choix de mode de soudure Frequency and Balance Frecuencia y balance Fréquence et équilibre Travel Menu Options Opciones del menú del recorrido Options de menu de voyage Travel Direction Direction de voyage Dirección del recorrido WFS/Amps Display Exhibición de WFS/Amps Affichage de WFS/Amps MSP Display Pantalla MSP Écran d Affichage MSP Volts/Trim Display Exhibición de voltios/ajuste Affichage de volts/équilibre VOLTS LED VOLTIOS DE LED VOLTS DE LED Trim LED Ajuste LED Équilibre LED Start Pushbutton Encienda el botón Mettez en marche le bouton poussoir Stop Pushbutton Pare el botón Arrêtez le bouton poussoir Set-up Menu Menú de la disposición Menu d'installation IR Port Puerto del IR Port d'ir Arc Start Options Opciones de comienzo del arco Options de début d'arc Arc End Options Opciones del final del arco Options de fin d'arc Inch Up Pulgada para arriba Pouce vers le haut Inch Down Pulgada abajo Pouce vers le bas Jog Sacudida Essai Memories Memorias Mémoires Figure 10-2 Pendant Controls

83 OPERATION Making a Weld 1. Set the travel speed. The travel speed range equals 10 to 100 in/min. Travel Speed 2. Select the weld mode

84 OPERATION Constant Current Operator presets current and desired voltage. The power source: - Maintains a constant arc length - Drives a constant current - Synergetically controls WFS to maintain voltage at the desired set point. Arc length is proportional to voltage. Constant current is traditionally used for larger diameter wires and slower travel speeds. AMPS Current Held Constant and Wire Feed Speed Varied and Constant Arc Length Maintained Extension Heating = VIR Arc Length = Varc Total Electrical Stickout V = Vir + Varc Wire Feed Speed Figure 10-3 Constant Current

85 OPERATION Constant Voltage Operator presets wire feed speed and desired voltage. The power source: - Maintains a constant arc length - Commands constant wire feed speed - Synergetically controls current to maintain voltage at the desired set point. Arc length is proportional to voltage. Constant voltage is traditionally used for smaller diameter wires and faster travel speeds. Current Varied AMPS and Wire Feed Held Constant and Maintain Constant Arc Length Extension Heating = VIR Total Electrical Stickout V = Vir + Varc Arc Length = Varc Wire Feed Speed Figure 10-4 Constant Voltage

86 OPERATION 3. Set the frequency (sine wave or square wave weld modes only). Range equals 10 to 100 Hz. Hertz Frequency 1, Use Frequency to Fine Tune Stability of Imbalanced Waveforms and Multiple Arc Systems ,000 Decrease Increase Turn Frequency Down Turn Frequency Up for for More Penetration More Stable Arc with (Less Energy) with a Less Penetration (More Less Stable Arc Energy in Less Time)

87 OPERATION 4. Set the balance (sine wave or square wave weld modes only). Range equals 25 to 75%. Percent Balance Variable Balance - Control Deposition By setting the correct wave balance (that is, the ratio between positive and negative waveforms), the operator is able to work faster and fill the weld joint with fewer passes. The Power Wave AC/DC 1000 has a wave balance range of 25 to 75%. 1, ,000 Nominal Balance Increased Balance More Penetration Less Deposition Decreased Balance Less Penetration More Deposition More positive wave equals more penetration More negative wave equals greater weld deposition

88 OPERATION Weld Sequence The weld sequence defines the weld procedure from beginning to end. All adjustments are made through the user interface. Arc Start Delay Strike Start Upslope Weld Downslope Crater Burnba ck Start Button Pressed Wire Begins to Feed Wire Touches Plate End of Upslope Stop Button Pressed End of Downslope End of Crater Timer Output Time End of Start Timer End of Burnback Start Options Figure 10-5 Weld Sequence The strike, start and upslope parameters are used at the beginning of the weld sequence to establish a stable arc and provide a smooth transition to the welding parameters. They are described in the following: Strike settings are valid from the beginning of the sequence (trigger) until the arc is established. They control run-in (speed at which the wire approaches the workpiece) and provide the power to establish the arc. Typically output levels are increased, and WFS is reduced during the strike portion of the weld sequence. Start values allow the arc to become stabilized once it is established. Extended start times or improperly set parameters can result in poor starting. Upslope determines the amount of time it takes to ramp from the start parameters to the weld parameters. The transition is linear and may be up or down depending on the relationship between the start and weld settings

89 OPERATION End Options The downslope, crater, and burnback parameters are used to define the end of the weld sequence. The are defined in the following: Downslope determines the amount of time it takes to ramp from the weld parameters to the crater parameters. The transition is linear and may be up or down depending on the relationship between the weld and crater settings. Crater parameters are typically used to fill the crater at the end of the weld and include both time and output settings. Burnback defines the amount of time the output remains on after the wire has stopped. This feature is used to prevent the wire from sticking in the weld puddle and to condition the end of the wire for the next weld. A burnback time of 0.4 second is sufficient in most applications. The output level for burnback is generally set to the same level as the last active weld sequence state (either weld or crater). Restrike Timer If the arc goes out for any reason (short circuit or open circuit), the system will enter restrike. During restrike, the WFS and outputs are driven in an attempt to re-establish the arc. The restrike timer determines how long the system will attempt to re-establish the arc before it shuts down. It is described in the following: A restrike timer is used to protect the welding system and/or work piece being welded. A restrike time of 1 to 2 seconds is sufficient in most applications

90 OPERATION 5. Set the DC offset (sine wave or square wave weld modes only). Percent DC Offset DC Offset (Variable Amplitude) - Control Penetration Wave amplitude and the duration of positive and negative cycles are independently adjustable, so the operator can obtain deep/shallow penetration and higher/lower deposition rates depending on the application. Increasing negative amplitude (offset) decreases penetration Nominal Offset Positive Offset More Penetration Less Deposition Negative Offset Less Penetration More Deposition Increasing positive amplitude (offset) increases penetration

91 OPERATION 6. Set the arc delay time. Range equals 0 to 5.0 seconds. Seconds Arc Delay Time

92 OPERATION WFS 7. Set the arc strike parameters. Range is dependent on gear ratio. Arc Strike. 8. Set the arc start parameters. 9. Set the burnback time. Range equals 0 to 2.0 seconds.. seconds Start Time 10. Configure the as desired with the setup menu. Use the setup to change the travel start and travel end options. See Setup Features Menu on page Position the on the joint

93 OPERATION Contact Tip 12. Travel to confirm the position of the guides and nozzle. Flux Nozzle Electrode Stickout Distance 13. Engage clutch. Auto 14. Select either Auto or Manual travel. Manual

94 OPERATION 15. Open the flux hopper valve. 16. Press the Start button to begin welding. Start 17. Press the Stop button to stop welding when the weld is complete. Stop

95 WELD MODE SEARCHING OPERATION The Weld Mode Search feature allows the selection of a welding mode based on certain criteria (wire size, process type, etc.). SEARCHING FOR A WELD MODE To search for a mode, press and release the control knob while the WELD MODE indicator is lit. Another way to search for a mode is to turn the control knob until Weld Mode Search is displayed. This will appear in between the highest and the lowest weld mode number. Once Weld Mode Search is displayed, pressing the right pushbutton labeled Begin will start the search process. During the search process, pressing the right pushbutton typically acts as a next button and the left pushbutton typically acts as a back button. Pressing the control knob also acts as a next button. Rotate the control knob then press to select relevant welding details such as welding process, wire type, wire size, etc. When the final selection is made, the will automatically change to the weld mode found by the Weld Mode Search process. Earlier products may not have this feature. To activate this feature, a software update may be needed from Memories The has four available memories. Each memory stores the following information: Weld mode Amperage (or WFS) Voltage Travel speed Frequency Balance DC offset Arc start options Arc end options. Recalling a Memory with Memory Buttons To recall a memory, press one of the four memory buttons. The memory is recalled when the button is released. Do not hold the button for more than 2 seconds. Recall a Memory: Press for 1 Second Figure 10-6 Recalling a Memory with Memory Buttons 10-18

96 OPERATION Saving a Memory with Memory Buttons To save a memory, press and hold the desired memory button for 2 seconds. When the button is initially pressed, the corresponding LED will illuminate. After 2 seconds, the LED will turn off. Do not hold the button for more than 5 seconds when saving a user memory. Save a Memory: Press for 2 Seconds Figure 10-7 Saving a Memory with Memory Buttons Note: Memories may be locked in the setup menu to prevent accidental overwrite of the memories. If an attempt is made to save a memory when memory saving is locked, the message Memory save is Disabled! will appear briefly in the MSP4 display

97 OPERATION Limits Limits allow the welder to adjust the welding procedure only within a defined range. Each memory may have a different set of limits. For example, memory 1 may limit the WFS to 100 through 120 in/min; memory 2 may limit the WFS to 140 through 160 in/min; and memory 3 may have no WFS limits. Parameters are constrained by machine limits or by setting memory limits. When memory limits are enabled, the parameter will flash whenever an attempt is made to exceed the memory limit value. The parameter will not flash if an attempt is made to exceed the machine limit. Set Limits: Press for 5 Seconds Note: Weld modes cannot be selected through the Limits Setup menu and must be chosen and saved to memory before entering the Limits Setup Menu. Setting Limits 1. Press the desired memory button 1 through 4 and hold for 5 seconds. Release the memory button when the LED begins to blink rapidly and the MSP4 displays Memory X Set Limits. Memory 2 Set Limits 2. If the passcode does not equal zero (0000), enter the passcode. If the passcode is unavailable or forgotten, a p.c. computer application or Palm O.S. application is required to change the passcode

98 OPERATION 3. If the passcode has been set to zero (0000), SETUP will illuminate on the MSP4 panel and display the following four items: Memory value High limit Low limit Parameter name. High Limit Memory Value Hi=200 Lo=180 Weld WFS Low Limit Parameter Name 4. One of the four items on the display panel will flash to indicate which item will change when the MSP4 encoder is rotated. Rotate the MSP4 encoder until the item that needs changed is flashing. Press the right button on the MSP4 panel to select the flashing item. Hi=200 Lo=180 Weld WFS Rotate to Change Value Press to Select Item to Change 5. The Limits Setup menu shows a list of all parameters available for the weld mode stored in the memory chosen. To lock a parameter to a specific value that cannot be changed, set 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. 6. After setting limits, press the memory button with the flashing LED. The MSP4 will ask to save or discard the limit changes just made

99 OPERATION 7. Press the left MSP4 button (YES) to save and enable limits and exit. Press the right MSP4 button (NO) to exit and leave limits unchanged. Enabling/Disabling Limits 1. Limits for each memory may be enabled or disabled by pressing and holding the appropriate memory button for 10 seconds. 2. Release the memory button when the MSP4 display shows the message shown to the right. Memory 2 Limits Enable/Disable 3. If the passcode does not equal zero, enter the passcode. If the passcode is zero (0000), SETUP will light, and the MSP4 display shows the message shown. Enable Limits? Yes No

100 OPERATION 4. Press the left MSP4 button (YES) to enable limits or the right MSP4 button (NO) to disable limits. Disabling limits does not change any limit values that may have been previously set. Enable Limits? Yes No

101 OPERATION Setup Features Menu The Setup Menu provides access for configuring user preferences, which are generally only set at installation. The user preferences are grouped as shown in the following table. 1. ACCESS PARAMETER P.1 through P.99 P.101 through P.199 P.501 through P.599 DEFINITION Unsecured Parameters (always adjustable) Diagnostic Parameters (always read only) Secured Parameters (only accessible with Weld Manager) ACCESSING THE SETUP MENU 3. PREFERENCE CHANGE To access the Setup Menu, Press the Left Button and Right Button simultaneously. The Setup Menu Indicator will light and the lower display will read as shown below. Note: The Setup Menu cannot be accessed during welding, or if a fault is displayed. To resume welding, exit the Setup Menu. 2. PREFERENCE SELECTION Scroll through the Preference list by rotating the Control Knob. Press the Right Button to edit the selected preference. Scroll through the preference options by rotating the Control Knob. Change the preference setting by pressing the Right Button. To cancel, press the Left Button. 4. EXIT To exit the Setup Menu, press both buttons simultaneously or select P.0 and press the Left Button. Sixty seconds of inactivity will automatically exit the Setup Menu. Note: If a product is missing any of the preference options listed below, a software update may be needed from FIGURE B.7 - SETUP MENU Mode Select Panel (MSP) User P. 0 Prefs Setup Menu Indicator Exit Left Button Control Knob Right Button

102 Parameter OPERATION USER DEFINED PARAMETERS Definition Exit Setup Menu P.0 This option is used to exit the setup menu. When P.0 is displayed, press the Left Button to exit the setup menu. P.1 Wire Feed Speed Units This option selects which units to use for displaying wire feed speed. English = inches/minute wire feed speed units (default). Metric = meters/minute wire feed speed units. P.2 Arc Display Mode This option selects what value will be shown on the upper left display while welding. Amps = The left display shows Amperage while welding (default). WFS = The left display shows Wire Feed Speed while welding. P.3 Display Options This setup parameter was previously named "Display Energy". If the previous software revision had this parameter set to display energy, that selection will remain. This option selects the information displayed on the alphanumeric displayes while welding. Not all P.3 selections will be available on all machines. In order for each selection to be included in the list, the power source must support that feature. A software update of the power source may be needed to include the features. Standard Display = The lower displays will continue to show preset information during and after a weld (default). Show Energy = Energy is displayed, along with time in HH:MM:SS format. Show Weld Score = The accumulative weld score result is shown. P.12 Travel Carriage Start/Stop - Travel Starts This option allows the adjustment of the start and end travel options for a travel carriage. Press the Right Button to enter the option and rotate the Control Knob to select either starting or ending options. Press the Right Button to enter the selected option. Rotate the Control Knob to select the desired function. After selecting the function, press the Left Button to save the function and back out to select another option. Rotate the Control Knob to make another selection, or press the Left Button to exit this option. P.12 Travel Carriage Start/Stop - Travel Ends This option allows the adjustment of the start and end travel options for a travel carriage. Press the Right Button to enter the option and rotate the Control Knob to select either starting or ending options. Press the Right Button to enter the selected option. Rotate the Control Knob to select the desired function. After selecting the function, press the Left Button to save the function and back out to select another option. Rotate the Control Knob to make another selection, or press the Left Button to exit this option. P.12 Tractor Wheel Size This option allows the adjustment of the wheel diameter used on the Cruiser dx Tractor only. Press the Right Button to enter the option and rotate the Control Knob to select Wheel Size. Press the Right Button to enter the selected option. Rotate the Control Knob to select the desired value. After selecting the value, press the Left Button to save the value and back out to select another option. Rotate the Control Knob to make another selection, or press the Left Button to exit this option. When the value is set to 5.65 ipm, the display will read "Track" indicating the track wheels are being used

103 OPERATION USER DEFINED PARAMETERS Parameter Definition P.12 Tractor Travel Speed This option allows the adjustment of the Tractor Travel Speed for the Cruiser dx Tractor only. Press the Right Button to enter the option and rotate the Control Knob to select Travel Speed. Press the Right Button to enter the selected option. Rotate the Control Knob to select the desired value. After selecting the value, press the Left Button to save the value and back out to select another option. Rotate the Control Knob to make another selection, or press the Left Button to exit this option. P.13 Arc Force Adjustment Options This option allows the adjustment of Arc Force values for Start, Weld and Crater. Press the Right Button to enter the option and rotate the Control Knob to select the desired weld state to adjust. Press the Right Button again to adjust the value on the upper Left Knob. Press the Left Button to save the value and back out to select another weld state. Rotate the Control Knob to make another selection, or press the Left Button to exit this option. This option will not appear if the presently selected weld mode does not support Arc Force. P.14 Reset Consumable Weight Use this option to reset the initial weight of the consumable package. Press the Right Button to reset the consumable weight. This option will only appear with systems using Production Monitoring. P.15 Hot-Inch Touch Sense Option This option allows enabling or disabling touch sense when feeding wire forward. Disabled = Touch sensing is disabled when feeding the wire forward (default). Enabled = Touch sensing is active when feeding the wire forward. When enabled and feeding wire forward, the wire is electrically "hot" and waiting to short to the plate. When a short occurs, the wire feed automatically stops and the flux hopper relay is activated until the feed forward button is released. P.18 Wire Drive Gear Ratio This option selects the Wire Drive Gear Ratio that will be used. This applies to the Cruiser dx Tractor and MAXsa 10 only. The possible selectable values are read from the Wire Drive on startup. Note: Changing this value will cause the system to reset. P.19 Wire Drive Direction This option selects the direction that the Wire Drive will run in. This applies to the Cruiser dx Tractor only. This option is useful since the Tractor's WD head can be rotated to "point" in different directions. P.21 Shutdown 2 Function Select This option allows selection of the Shutdown 2 input function on the control box. Normal Shutdown = The Shutdown 2 input functions as a standard shutdown input that locks out all input buttons (default). Output Disable = The Shutdown 2 input functions as a machine output lockout to disable the welding circuit but still allow cold feeding of the wire. P.80 Sense From Studs Use this option for diagnostic purposes only. When power is cycled, this option is automatically reset to False. False = Voltage sensing is automatically determined by the selected weld mode and other machine settings (default). True = Voltage sensing is forced to "studs"

104 OPERATION USER DEFINED PARAMETERS (CONT.) Parameter Definition P.99 Show Test Modes? Most power sources contain weld modes used for calibration and test purposes. By default, the machine does not include test weld modes in the list of weld modes that are available to the operator. To manually select a test weld mode, set this option to "Yes". When the power source is turned off and back on again, the test modes will no longer appear in the mode list. Test weld modes typically require the machine output to be connected to a grid load and cannot be used for welding. P.100 View Diags? Diagnostics are only used for servicing or troubleshooting the Power Wave system. Select "Yes" to access the diagnostic options in the menu. Additional parameters will now appear in the setup menu (P.101, P.102, etc). P.101 View Event Logs Used for viewing all the system event logs. Press the Right Button to enter the option. Rotate Control Knob to select the desired event log to read. Press the Right Button again to enter the selected log. Rotating the Control Knob will scroll through the event log, displaying the log index number, event code and some other data. Press the Left Button to back out to select another log. Press the Left Button again to exit this option. P.102 View Fatal Logs Used for viewing all the system fatal logs. Press the Right Button to enter the option. Rotate Control Knob to select the desired fatal log to read. Press the Right Button again to enter that log. Rotating the Control Knob will scroll through the log, displaying the log index number and fatal code. Press the Left Button to back out to select another log. Press the Left Button again to exit this option. P.103 View Software Version Info Used for viewing the software versions for each board in the system. Press the Right Button to enter the option. Rotate Control Knob to select the desired board to read. Press the Right Button again to read the firmware version. Press the Left Button to back out to select another board. Rotate the Control Knob to select another board, or press the Left Button to exit this option. P.104 View Hardware Version Info Used for viewing the hardware version for each board in the system. Press the Right Button to enter the option. Rotate Control Knob to select the desired board to read. Press the Right Button again to read the hardware version. Press the Left Button to back out to select another board. Press the Left Button again to exit this option. P.105 View Welding Software Info Used for viewing the Weld Set in the Power Source. Press the Right Button to read the Weld Set version. Press the Left Button to back out and exit this option. P.106 View Ethernet IP Address Used for viewing the IP address of Ethernet compatible equipment. Press the Right Button to read the IP Address. Press the Left Button to back out and exit this option. The IP address cannot be changed using this option P.107 View Power Source Protocol Used for viewing the type of power source the feeder is connected to. Press the Right Button to identify the power source as either LincNet or ArcLink. Press the Left Button to back out and exit this option

105 OPERATION USER DEFINED PARAMETERS (CONT.) Parameter Definition P.501 Encoder Lockout Locks one or both of the upper knobs (encoders), preventing the operator from changing wire feed speed, amps, volts or trim. The function of each upper knob depends on the selected weld mode. When a constant current weld mode is selected (e.g. Stick, TIG, Gouge), the upper right knob will always function as an on/off switch. This parameter can only be accessed using PowerWave Manager software. P.502 Memory Change Lockout Determines if the memories can be overwritten with new contents. No = Memories can be saved and limits can be configured (default). Yes = Memories cannot be changed - saving is prohibited and limits cannot be re-configured. This parameter can only be accessed using Power Wave Manager software. P.503 Memory Button Disable Disables the specified memory button(s). When a memory is disabled, welding procedures cannot be restored from or saved to that memory. If an attempt is made to save or restore a disabled memory, a message will be displayed on the lower display indicating the memory number is disabled. In multi-head systems, this parameter disables the same memory buttons on both feed heads. This parameter can only be accessed using Power Wave Manager software. P.504 Mode Select Panel Lock Selects between several Mode Select Panel lockout preferences. When a Mode Select Panel selection is locked and an attempt is made to change that parameter, a message will be displayed on the lower display indicating the parameter is locked. All MSP Options Unlocked = All adjustable parameters on the Mode Select Panel are unlocked. All MSP Options Locked = All knobs and buttons on the Mode Select Panel are locked. Start & End Options Locked = The Start and End parameters on the Mode Select Panel are locked, all others are unlocked. Weld Mode Option Locked = The weld mode cannot be changed from the Mode Select Panel, all others Mode Select Panel settings are unlocked. Wave Control Options Locked = The Wave Control parameters on the Mode Select Panel are locked, all others are unlocked. Start, End, Wave Options Locked = The Start, End and Wave Control parameters on the Mode Select Panel are locked, all others are unlocked. Start, End, Mode Options Locked = The Start, End and Weld Mode Select parameters on the Mode Select Panel are locked, all others are unlocked. This parameter can only be accessed using Power Wave Manager software. P.505 Setup Menu Lock Determines if the setup parameters can be modified by the operator without entering a passcode. No = The operator can change any set menu parameter without first entering the passcode even if the passcode is non-zero (default). Yes = The operator must enter the passcode (if the passcode is non-zero) in order to change any setup menu parameters. This parameter can only be accessed using Power Wave Manager software

106 OPERATION USER DEFINED PARAMETERS Parameter Definition P.506 Set User Interface Passcode Prevents unauthorized changes to the equipment. The default passcode is zero which allows full access. A nonzero passcode will prevent unauthorized: changes to memory limits, saving to memory (if P.502 = Yes), changes to setup parameters (if P.505 = Yes). This parameter can only be accessed using Power Wave Manager software. P.509 UI Master Lockout Locks all user interface controls, preventing the operator from making any changes. This parameter can only be accessed using Power Wave Manager software. TOUCH SENSE 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 and the flux hopper (if used) will activate to put flux around the wire and fill the flux feed system. The flux hopper will stay active until the Feed Forward button is released. WARNING If the Touch Sense is enabled the Power Source output is ON as long as the Feed Forward button is held. Avoid touching any portion of the weld circuit while feeding down. 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 and the flux hopper will not activate. Moving the The will not automatically travel unless the clutch is engaged. To engage the clutch, rotate the handle upwards. To disengage the clutch, rotate the handle downwards. Figure 10-8 Rotate Handle Downwards to Disengage Clutch and Upwards to Engage Clutch. Driving the Without Welding 1. Engage the clutch at the rear of the Cruiser tractor

107 OPERATION Forward Reverse 2. Select either forward or reverse travel on the pendant. Press and release the travel button until the desired directional arrow is lit. Direction Button 3. Press and hold the jog button or place the toggle switch in the MANUAL travel position. The will move in the direction chosen in step 2. Jog Button 4. To stop the Cruiser tractor, release the jog button or turn the toggle switch to the STOP position. Toggle Switch in Manual Travel Position

108 TROUBLESHOOTING AND MAINTENANCE Troubleshooting and Maintenance Troubleshooting CAUTION If for any reason a user does not understand the test procedures or is unable to perform the tests/repairs safely, contact a local authorized Lincoln Electric Field Service Facility for technical assistance. Observe all safety guidelines detailed in the beginning and throughout this manual

109 TROUBLESHOOTING AND MAINTENANCE Problems (Symptoms) Frequency and balance do not appear on the display. The wire feeder does not feed wire, and drive rolls do not spin. The wire feeds erratically, or a motor overload error occurs. The wire drive feeds wire in the wrong direction. The wire feed system is consistently wrong but not the maximum value. When the inch speed is adjusted, the wire feed system changes. Output Problems Possible Areas of Misadjustment(s) 1. A DC waveform has been selected. 1. Verify the power source is turned on. 2. Verify the circuit breaker for the wire feeder power on the power source has not tripped. 3. Verify power is being supplied to the wire feeder. 4. Verify the cable to the wire drive is connected to the base of the Cruiser tractor. 5. Inspect the brushes on the wire drive motor. 1. Verify the correct drive rolls and guides are installed in the wire drive. 2. Check for sharp bends in the wire path. 3. Examine the contact tip for wear and proper size. 4. The pressure arm setting is too high. 5. Verify the coil of wire rotates with no more than moderate resistance. 6. Inspect the brushes on the wire drive motor. 1. P19 parameter is set wrong. 1. Verify that parameter P18 and gear ratio installed in the wire drive match. The Cruiser tractor ships with 142:1 gears. Recommended Course of Action 1. Switch to square wave or sine wave mode. 1. Turn on the welding power source. 2. Reset the breaker. If the breaker breaker tripping. 3. Ensure the Cruiser tractor cable connects to a power source that is turned ON. 4. Connect the wire drive cable if disconnected. 5. Replace the brushes if less than 1/4 inch long. 1. Replace the drive rolls and guides if necessary. 2. Route the wire path to eliminate sharp bends. 3. Replace the contact tip if worn. 4. Reduce pressure on the pressure arm. 5. Reduce the spindle brake friction. 6. Replace the wire drive motor brushes. 1. Change parameter P19 in the setup menu. 1. Change P18 in the setup menu to match the gear ratio installed in the wire drive

110 TROUBLESHOOTING AND MAINTENANCE Problems (Symptoms) The wire feed system runs at maximum. The wire feed system feeds in only one direction. The Cruiser tractor travels in only one direction. The Cruiser tractor does not travel. The Cruiser tractor travels only at a fast speed. Output Problems Possible Areas of Misadjustment(s) 1. Check the tachometer leads connecting the wire drive cable to the Cruiser tractor base. Recommended Course of Action 1. Repair the tachometer leads, or replace the tachometer. 1. Check the wire drive relay. 1. Replace the wire drive relay if bad. 1. Check the travel relay. 1. Replace the travel relay if bad. 1. Verify the clutch is engaged. 2. Verify the rear wheels are tightened to the axle. 3. Verify the worm on the travel motor spins. 4. Inspect the travel motor brushes. 1. Verify the travel motor tachometer is operating correctly. 1. Engage the clutch if not engaged. 2. Tighten the nuts holding the rear wheels to the axle to 60 ft-lbs with the clutch disengaged. 3. Replace the key holding the worm to the motor shaft. 4. Replace the travel motor brushes 1. Replace the travel motor tachometer if bad

111 TROUBLESHOOTING AND MAINTENANCE Routine Lubricate clutch Maintenance Procedure Blow out slides Periodic Check motor brushes Lubricate wire drive gearbox

112 SOFTWARE INSTALLATION Software Installation The software in the power source may need to be updated before the will operate properly. Verify the power source is configured as a master and not as a slave. Connecting the to a Computer 1. Computer (PC or laptop) with a Serial Port. A welder can be upgraded through the computer s serial port if one is available. The port is a DE-9 (9- pin) male connector. DE-9 Male Connector 2. Computer (PC or laptop) with a USB Port. If a computer does not have a serial port, the welder can be upgraded through one of the computer s USB ports with the use of a USB-to-Serial adapter. See step 3, Connection Cable, on page USB Connection

113 SOFTWARE INSTALLATION 3. Connection Cable. Upgrading a welder will require a serial cable, usually called a serial modem cable with a DE-9 male and DB-25 female connectors. Various electronic stores carry this type of cable. To upgrade the welder through a USB port, a user will also need a USB-to-Serial adapter, which transforms a USB port into a serial port for computers with no built-in serial ports. Various electronic stores carry this type of adapter. Note: Connection cables are not sold through Lincoln Electric

114 SOFTWARE INSTALLATION Updating Software 1. While connected to the Internet, navigate to: 2. Log into the Web site by typing in an address and password. If a user does not have a login, click on the Register today link. Once logged in, click on the desired product family (such as Power Wave) to navigate to that product s download page. Click on the Download link to begin downloading the update package for the selected product

115 SOFTWARE INSTALLATION 3. Before downloading begins, a dialog box will pop up asking for the location where the update package should be saved. Select a convenient location, such as the Desktop, to save the update package. Note: After this step, an Internet connection is no longer required. 4. Connect the 25-pin end of the serial cable to the welder. Note: The location of the serial connector may vary between different welder models. 5. Connect the other end of the serial cable to the computer. If a user is using a USB-to-Serial adapter, plug the serial cable into the adapter and then plug the adapter into the USB port on the computer. Note: Ensure the drivers for the USB-to- Serial adapter are properly installed before using it to upgrade the welder

116 SOFTWARE INSTALLATION 6. Double-click on the update package that was downloaded from the Web site. This will launch the Lincoln Electric System Update Utility, which will guide a user through the upgrade process. Select the option Connect through the serial port to tell the system update utility how it should communicate with the welder. 7. Follow the on-screen instructions given by the system update utility. Note: If user does not want to overwrite the existing weld sets (that is, if a user has a customer-specific weld set), or backup the existing weld sets, the system update utility gives the option

117 NOTES

118 KITS AND ACCESSORIES Kits and Accessories Optional Kits and Accessories K Tube and Clamp Kit K Pendant K Cross Slide Assembly Optional Kits and Accessories Includes: Two 15-inch splined tubes, two 30-inch splined tubes, four clamps with keys and handles and mounting hardware. Includes: One Cruiser tractor pendant with 4 ft. (1.2 m) of cable. (One pendant included with each Cruiser tractor.) Includes: Two slides with 4 inches (101.6 mm) of travel. (One cross slide assembly included with each Cruiser tractor.) K396 Track Section Includes: A single section of 70 inches (1.8 m) of track. KP Conduit Includes: White conduit 5 feet (1.5 m) in length. K1543-xx K2683-xx K ArcLink Control Cable ArcLink Control Cable, Heavy Duty 50 to 60 lb Coil Adapter Includes: A 5 pin to 5 pin Cruiser tractor to power source control cable. Cables may be connected end-to-end to make a longer cable. Connectors are black anodized aluminum. Includes: A 5 pin to 5 pin Cruiser tractor to power source control cable. Cables may be connected end-to-end to make a longer cable. The female connector is a brass spin nut. The male connector is made from stainless steel. Includes: One coil adapter for use with 2-inch spindles. (One coil adapter is included with each Cruiser tractor.)

119 KITS AND ACCESSORIES Drive Roll and Guide Tube Kits Drive Roll and Guide Tube Kits 1 K Wire Straightener 1 2 KP Drive Roll/Guide Tube Kit, 3/32-7/32 KP Drive Roll/Guide Tube Kit, 1/16, 5/64, 3/32 KP Drive Roll/Guide Tube Kit, 035, 045, 052 KP Drive Roll/Guide Tube Kit, 045, 052 cored

120 KITS AND ACCESSORIES Drive Roll and Guide Tube Kits 3 K231-5/64 (nozzles rated up to 600 amps) K231-3/32 (nozzles rated up to 600 amps) K231-1/8 (nozzles rated up to 600 amps) K231-5/32 (nozzles rated up to 600 amps) K231-3/16 (nozzles rated up to 600 amps) K231-7/32 (nozzles rated up to 600 amps) Contact Nozzle Assembly, 5/64 (2.0 mm) Contact Nozzle Assembly, 3/32 (2.4 mm) Contact Nozzle Assembly, 1/8 (3.2 mm) Contact Nozzle Assembly, 5/32 (4.0 mm) Contact Nozzle Assembly, 3/16 (4.8 mm) Contact Nozzle Assembly, 7/32 (5.6 mm)

121 KITS AND ACCESSORIES 4 KP Nozzle Extension (if required) Drive Roll and Guide Tube Kits 4 5 KP1962-3B1 Contact Tip, 3/32 KP1962-1B1 Contact Tip, 1/8 KP1962-4B1 Contact Tip, 5/32 KP1962-2B1 Contact Tip, 3/16 5 KP1962-5B1 Contact Tip, 7/32 6 T12929 Flux Hose Clamp

122 KITS AND ACCESSORIES 7 T11807 Nozzle Extension Insulator Drive Roll and Guide Tube Kits 7 8 K148A (nozzles rated up to 1,000 amps) K148B (nozzles rated up to 1,000 amps) Positive Contact Nozzle for 3/22- to 1/8-inch (2.4 to 3.2 mm) Wire Positive Contact Nozzle for 5/32- to 3/16-inch (4.0 to 4.8 mm) Wire

123 KITS AND ACCESSORIES Drive Roll and Guide Tube Kits 9 M13739 Nozzle Adapter 8-inch (203 mm) M Nozzle Adapter 2.25-inch (57 mm) 9 10 K285 Concentric Flux Cone Assembly

124 DIAGRAMS

125 NOTES

126 WARNING Do not touch electrically live parts or electrode with skin or wet clothing. Insulate yourself from work and ground. Keep flammable materials away. Wear eye, ear and body protection. Spanish AVISO DE PRECAUCION No toque las partes o los electrodos bajo carga con la piel o ropa mojada. Aislese del trabajo y de la tierra. Mantenga el material combustible fuera del área de trabajo. Protéjase los ojos, los oídos y el cuerpo. French ATTENTION Ne laissez ni la peau ni des vêtements mouillés entrer en contact avec des pièces sous tension. Isolez-vous du travail et de la terre. Gardez à l écart de tout matériel inflammable. Protégez vos yeux, vos oreilles et votre corps. German WARNUNG Portuguese ATENÇÃO Berühren Sie keine stromführenden Teile oder Elektroden mit Ihrem Körper oder feuchter Kleidung! Isolieren Sie sich von den Elektroden und dem Erdboden! Não toque partes elétricas e electrodos com a pele ou roupa molhada. Isole-se da peça e terra. Entfernen Sie brennbarres Material! Mantenha inflamáveis bem guardados. Tragen Sie Augen-, Ohren- und Körperschutz! Use proteção para a vista, ouvido e corpo. Japanese Chinese Korean Arabic READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR. LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EM- PLOYEUR. LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRO- DENEINSATZ DES HERSTELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

127 Keep your head out of fumes. Use ventilation or exhaust to remove fumes from breathing zone. Turn power off before servicing. Do not operate with panel open or guards off. WARNING Los humos fuera de la zona de respiración. Mantenga la cabeza fuera de los humos. Utilice ventilación o aspiración para gases. Desconectar el cable de alimentación de poder de la máquina antes de iniciar cualquier servicio. No operar con panel abierto o guardas quitadas. Spanish AVISO DE PRECAUCION Gardez la tête à l écart des fumées. Utilisez un ventilateur ou un aspirateur pour ôter les fumées des zones de travail. Débranchez le courant avant l entretien. N opérez pas avec les panneaux ouverts ou avec les dispositifs de protection enlevés. French ATTENTION Vermeiden Sie das Einatmen von Schweibrauch! Sorgen Sie für gute Be- und Entlüftung des Arbeitsplatzes! Strom vor Wartungsarbeiten abschalten! (Netzstrom völlig öffnen; Maschine anhalten!) Anlage nie ohne Schutzgehäuse oder Innenschutzverkleidung in Betrieb setzen! German WARNUNG Mantenha seu rosto da fumaça. Use ventilação e exhaustão para remover fumo da zona respiratória. Não opere com as tampas removidas. Desligue a corrente antes de fazer serviço. Não toque as partes elétricas nuas. Mantenha-se afastado das partes moventes. Não opere com os paineis abertos ou guardas removidas. Portuguese ATENÇÃO Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR.