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IP23S

Sales and Service through Subsidiaries and Distributors Worldwide

Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

World's Leader in Welding and Cutting Products

CRUISER

OPERATORS MANUAL

IM10098-AJuly, 2012

Safety Depends on YouLincoln arc welding and cutting

equipment is designed and built

with safety in mind. However,

your overall safety can be

increased by proper installation

... and thoughtful operation on

your part. DO NOT INSTALL,

OPERATE OR REPAIR THIS

EQUIPMENT WITHOUT READ-

ING THIS MANUAL AND THE

SAFETY PRECAUTIONS CON-

TAINED THROUGHOUT. And,

most importantly, think before

you act and be careful.

For use with machines having Code Numbers: 11767, 11947

Copyright Lincoln Global Inc.

RETURN TO MAIN MENU

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FOR ENGINEpowered equipment.

1.a. Turn the engine off before troubleshooting and maintenancework unless the maintenance work requires it to be running.

____________________________________________________1.b.Operate engines in open, well-ventilated

areas or vent the engine exhaust fumesoutdoors.

____________________________________________________1.c. Do not add the fuel near an open flame weld-

ing arc or when the engine is running. Stopthe engine and allow it to cool before refuel-ing to prevent spilled fuel from vaporizing oncontact with hot engine parts and igniting. Donot spill fuel when filling tank. If fuel is spilled,wipe it up and do not start engine until fumeshave been eliminated.

____________________________________________________

1.d. Keep all equipment safety guards, covers and devices in posi-

tion 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 guardsto perform required maintenance. Remove guards only whennecessary and replace them when the maintenance requiringtheir removal is complete. Always use the greatest care whenworking near moving parts.

___________________________________________________

1.f. Do not put your hands near the engine fan.Do not attempt to override the governor oridler by pushing on the throttle control rodswhile the engine is running.

___________________________________________________1.g. To prevent accidentally starting gasoline engines while turn-

ing the engine or welding generator during maintenancework, disconnect the spark plug wires, distributor cap ormagneto wire as appropriate.

iSAFETYi

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 youpurchase a copy of Safety in Welding & Cutting - ANSI Standard Z49.1 from the American Welding Society, P.O. Box

351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of Arc Welding Safety booklet E205 is availablefrom the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE

PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

WARNING

ELECTRIC ANDMAGNETIC FIELDSmay be dangerous

2.a. Electric current flowing through any conductor causes

localized Electric and Magnetic Fields (EMF). Welding

current creates EMF fields around welding cables and

welding machines

2.b. EMF fields may interfere with some pacemakers, and

welders having a pacemaker should consult their physician

before welding.

2.c. Exposure to EMF fields in welding may have other health

effects which are now not known.

2.d. All welders should use the following procedures in order to

minimize exposure to EMF fields from the welding circuit:

2.d.1. Route the electrode and work cables together - Secure

them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode and

work cables. If the electrode cable is on your right

side, the work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close as

possible to the area being welded.

2.d.5. Do not work next to welding power source.

1.h. To avoid scalding, do not remove theradiator pressure cap when the engine ishot.

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituentsare known to the State of California to cause can-cer, birth defects, and other reproductive harm.

The engine exhaust from this product containschemicals known to the State of California to causecancer, birth defects, or other reproductive harm.

The Above For Diesel Engines The Above For Gasoline Engines

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ARC RAYS can burn.4.a. Use a shield with the proper filter and cover

plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistantmaterial to protect your skin and that of your helpers fromthe arc rays.

4.c. Protect other nearby personnel with suitable, non-flammablescreening and/or warn them not to watch the arc nor exposethemselves to the arc rays or to hot spatter or metal.

ELECTRIC SHOCK can kill.3.a. The electrode and work (or ground) circuits

are electrically hot when the welder is on.

Do not touch these hot parts with your bare

skin or wet clothing. Wear dry, hole-free

gloves to insulate hands.

3.b. Insulate yourself from work and ground using dry insulation.

Make certain the insulation is large enough to cover your full

area of physical contact with work and ground.

In addition to the normal safety precautions, if welding

must be performed under electrically hazardous

conditions (in damp locations or while wearing wet

clothing; on metal structures such as floors, gratings or

scaffolds; when in cramped positions such as sitting,

kneeling or lying, if there is a high risk of unavoidable or

accidental contact with the workpiece or ground) use

the following equipment:

Semiautomatic DC Constant Voltage (Wire) Welder.

DC Manual (Stick) Welder.

AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode,

electrode reel, welding head, nozzle or semiautomatic

welding gun are also electrically hot.

3.d. Always be sure the work cable makes a good electrical

connection with the metal being welded. The connection

should be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical

(earth) ground.

3.f. Maintain the electrode holder, work clamp, welding cable and

welding machine in good, safe operating condition. Replacedamaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically hot parts ofelectrode 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.

iiSAFETYii

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 specialventilation 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 ven-

tilation. In confined spaces or in some circumstances,

outdoors, a respirator may be required. Additional pre-

cautions are also required when welding on galvanized

steel.

5. b. The operation of welding fume control equipment is affect-

ed 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 applica-

ble 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 irritatingproducts.

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 manufacturers instructions for this

equipment and the consumables to be used, including the

material safety data sheet (MSDS) and follow your

employers safety practices. MSDS forms are available from

your welding distributor or from the manufacturer.

5.f. Also see item 1.b.

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FOR ELECTRICALLYpowered equipment.

8.a. Turn off input power using the disconnectswitch at the fuse box before working onthe equipment.

8.b. Install equipment in accordance with the U.S. NationalElectrical Code, all local codes and the manufacturersrecommendations.

8.c. Ground the equipment in accordance with the U.S. NationalElectrical Code and the manufacturers recommendations.

CYLINDER may explode

if damaged.7.a. Use only compressed gas cylinders

containing the correct shielding gas for theprocess used and properly operatingregulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable forthe application and maintained in good condition.

7.b. Always keep cylinders in an upright position securelychained to an undercarriage or fixed support.

7.c. Cylinders should be located: Away from areas where they may be struck or subjected tophysical damage.

A safe distance from arc welding or cutting operations andany other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any otherelectrically hot parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outletwhen opening the cylinder valve.

7.f. Valve protection caps should always be in place and handtight except when the cylinder is in use or connected foruse.

7.g. Read and follow the instructions on compressed gascylinders, associated equipment, and CGA publication P-l,Precautions for Safe Handling of Compressed Gases inCylinders, available from the Compressed Gas Association1235 Jefferson Davis Highway, Arlington, VA 22202.

WELDING and CUTTINGSPARKS cancause fire or explosion.6.a. Remove fire hazards from the welding area.

If this is not possible, cover them to preventthe welding sparks from starting a fire.

Remember that welding sparks and hot materials from weld-ing can easily go through small cracks and openings to adja-cent 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 hazardoussituations. Refer to Safety in Welding and Cutting (ANSIStandard Z49.1) and the operating information for theequipment being used.

6.c. When not welding, make certain no part of the electrodecircuit is touching the work or ground. Accidental contactcan cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until theproper steps have been taken to insure that such procedureswill not cause flammable or toxic vapors from substancesinside. They can cause an explosion even though they have

been cleaned. For information, purchase RecommendedSafe Practices for the Preparation for Welding and Cutting ofContainers and Piping That Have Held HazardousSubstances, AWS F4.1 from the American Welding Society

(see address above).

6.e. Vent hollow castings or containers before heating, cutting orwelding. They may explode.

6.f. Sparks and spatter are thrown from the welding arc. Wear oilfree protective garments such as leather gloves, heavy shirt,cuffless trousers, high shoes and a cap over your hair. Wearear plugs when welding out of position or in confined places.Always wear safety glasses with side shields when in awelding area.

6.g. Connect the work cable to the work as close to the weldingarea as practical. Work cables connected to the buildingframework or other locations away from the welding areaincrease the possibility of the welding current passingthrough lifting chains, crane cables or other alternate cir-cuits. This can create fire hazards or overheat lifting chainsor cables until they fail.

6.h. Also see item 1.c.

6.I. Read and follow NFPA 51B Standard for Fire PreventionDuring Welding, Cutting and Other Hot Work, availablefrom NFPA, 1 Batterymarch Park, PO box 9101, Quincy,Ma 022690-9101.

6.j. Do not use a welding power source for pipe thawing.

iiiSAFETYiii

Refer to http://www.lincolnelectric.com/safety for additional safety information.

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PRCAUTIONS DE SRETPour votre propre protection lire et observer toutes les instruc-

tions et les prcautions de sret specifiques qui parraissent

dans ce manuel aussi bien que les prcautions de sret

gnrales suivantes:

Sret Pour Soudage A LArc1. Protegez-vous contre la secousse lectrique:

a. Les circuits llectrode et la pice sont sous tension

quand la machine souder est en marche. Eviter toujours

tout contact entre les parties sous tension et la peau nue

ou les vtements mouills. Porter des gants secs et sans

trous pour isoler les mains.

b. Faire trs attention de bien sisoler 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 couch pour lesquelles une

grande partie du corps peut tre en contact avec la

masse.

c. Maintenir le porte-lectrode, la pince de masse, le cble

de soudage et la machine souder en bon et sr tatdefonctionnement.

d.Ne jamais plonger le porte-lectrode dans leau pour le

refroidir.

e. Ne jamais toucher simultanment les parties sous tension

des porte-lectrodes connects deux machines soud-

er parce que la tension entre les deux pinces peut tre le

total de la tension vide des deux machines.

f. Si on utilise la machine souder comme une source de

courant pour soudage semi-automatique, ces precautions

pour le porte-lectrode sapplicuent aussi au pistolet de

soudage.

2. Dans le cas de travail au dessus du niveau du sol, se pro-tger contre les chutes dans le cas ou on recoit un choc. Ne

jamais enrouler le cble-lectrode autour de nimporte quelle

partie du corps.

3. Un coup darc peut tre plus svre quun coup de soliel,

donc:

a. Utiliser un bon masque avec un verre filtrant appropri

ainsi quun verre blanc afin de se protger les yeux du

rayonnement de larc et des projections quand on soude

ou quand on regarde larc.

b. Porter des vtements convenables afin de protger la

peau de soudeur et des aides contre le rayonnement de

larc.

c. Protger lautre personnel travaillant proximit au

soudage laide dcrans appropris et non-inflamma-

bles.

4. Des gouttes de laitier en fusion sont mises de larc de

soudage. Se protger avec des vtements de protection

libres de lhuile, tels que les gants en cuir, chemise paisse,

pantalons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de scurit dans la zone de

soudage. Utiliser des lunettes avec crans lateraux dans les

zones o lon pique le laitier.

6. Eloigner les matriaux inflammables ou les recouvrir afin de

prvenir tout risque dincendie d aux tincelles.

7. Quand on ne soude pas, poser la pince une endroit isol

de la masse. Un court-circuit accidental peut provoquer un

chauffement et un risque dincendie.

8. Sassurer que la masse est connecte le plus prs possible

de la zone de travail quil est pratique de le faire. Si on place

la masse sur la charpente de la construction ou dautres

endroits loigns de la zone de travail, on augmente le risque

de voir passer le courant de soudage par les chaines de lev-

age, cbles de grue, ou autres circuits. Cela peut provoquer

des risques dincendie ou dechauffement des chaines et des

cbles jusqu ce quils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage.

Ceci est particulirement important pour le soudage de tles

galvanises plombes, ou cadmies ou tout autre mtal quiproduit des fumes toxiques.

10. Ne pas souder en prsence de vapeurs de chlore provenant

doprations de dgraissage, nettoyage ou pistolage. La

chaleur ou les rayons de larc peuvent ragir avec les

vapeurs du solvant pour produire du phosgne (gas forte-

ment toxique) ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sret,

voir le code Code for safety in welding and cutting CSA

Standard W 117.2-1974.

PRCAUTIONS DE SRET POURLES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR

1. Relier la terre le chassis du poste conformement au code

de llectricit et aux recommendations du fabricant. Le dis-

positif de montage ou la piece souder doit tre branch

une bonne mise la terre.

2. Autant que possible, Iinstallation et lentretien du poste

seront effectus par un lectricien qualifi.

3. Avant de faires des travaux linterieur de poste, la

debrancher linterrupteur la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sret leur

place.

ivSAFETYiv

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vv

Thank Youfor selecting a QUALITY product by Lincoln Electric. We want

you to take pride in operating this Lincoln Electric Company prod-uct as much pride as we have in bringing this product to you!

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 protec-

tion. 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.

This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.

CAUTION

Please Examine Carton and Equipment For Damage ImmediatelyWhen 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 companyat 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 youhave recorded above. The code number is especially important when identifying the correct replacement parts.

CUSTOMER ASSISTANCE POLICYThe business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cuttingequipment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may askLincoln Electric for advice or information about their use of our products. We respond to our customers based on the best information in ourpossession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect tosuch information or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customers particularpurpose, 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, expandor 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 con-trol of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtainedin applying these types of fabrication methods and service requirements.

Subject to Change This information is accurate to the best of our knowledge at the time of printing. Please refer towww.lincolnelectric.com for any updated information.

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 www.lincolnelectric.com. Choose Support and then RegisterYour Product. Please complete the form and submit your registration.

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vivi TABLE OF CONTENTSPage

Installation.......................................................................................................................Section ATechnical Specifications.......................................................................................................A-1

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

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

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

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

Location................................................................................................................................A-3General Assembly ................................................................................................................A-4Outriggers, Manual Steering Mechanism, Assembly ...........................................................A-5

Manual Steering Mechanism, Adjustment............................................................................A-6Cross Slide ...........................................................................................................................A-6

Wire Reel Spindle.................................................................................................................A-6Wire Wheel Enclosure ..................................................................................................A-7, A-8

Take-Off Arm........................................................................................................................A-9

Wire Straightener Adjustment ............................................................................................A-10Feedplate Rotation .............................................................................................................A-10

Flux Hopper, Cables...........................................................................................................A-11Cable Connections, Weld Cable Sizes...............................................................................A-12

System Set-Up ...................................................................................................................A-13

Butt Joints ..................................................................................................................A-14/A-17

Fillet Joints.................................................................................................................A-17/A-18Horizontal Fillet ..........................................................................................................A-19/A-20Flat Fillet ....................................................................................................................A-21/A-22

Pipe Welding..............................................................................................................A-23/A-24

Base Dimensions Only .......................................................................................................A-25

________________________________________________________________________________Operation.........................................................................................................................Section B

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

Pendant Controls..................................................................................................................B-2Moving The Tractor ..............................................................................................................B-2

Laser Pointer, Touch Sense.................................................................................................B-3

Power-Up Sequence ............................................................................................................B-3Wire Feeder Setup ...............................................................................................................B-4

Changing And Setting Weld Modes .....................................................................................B-4

Frequency ............................................................................................................................B-4Balance Adjust .....................................................................................................................B-5

Offset Adjust.........................................................................................................................B-5Weld Sequence ....................................................................................................................B-5

Start Options ........................................................................................................................B-5Start Options Operation........................................................................................................B-6

End Options, End Options Operation ...................................................................................B-6

Memories..............................................................................................................................B-7Limits .............................................................................................................................B-7/B-9

Dip Switches.........................................................................................................................B-9Set-Up Features Menu ..............................................................................................B-10/B-12

________________________________________________________________________________

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

Optional Kits and Accessories ..............................................................................C-1

Drive Roll and Guide Tube Kits .............................................................................C-1Accessories Included with the CRUISER ..........................................................C-2

________________________________________________________________________________

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

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

________________________________________________________________________________

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

How to Use Troubleshooting Guide.......................................................................E-1Troubleshooting Guide...................................................................................E-2, E-3

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

________________________________________________________________________________

Parts Pages ............ .............. .............. ............. .............. .............. ............. .............. ................P-683

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A-1INSTALLATION

CRUISER

A-1

TECHNICAL SPECIFICATIONS - CRUISER K-3048-1

Wire Feeders - Input Voltage and CurrentVOLTAGE INPUT AMPERES

40 VDC 8 AMPS

Rated Output

DUTY CYCLE AMPERES

100% 1000 AMPS

Physical Dimensions (as shipped from the factory)*(Overall Size and Weight Dependent Upon Configuration)

MODEL HEIGHT WIDTH DEPTH WEIGHT

K3048-1 29 In (736 mm) 23 in (548 mm) 36 in (914 mm) 207 lb (94 kg)

Temperature RangesOperating Temperature -40F to 122F (-40C to +50C)

Storage Temperature -40F to 185F (-40C to +85C)

SAW

GEARING WFS Range Wire Sizes

50 to 500 ipm(1.3 to 12.5 m/min)

15 to 300 ipm(0.4 to 7.5 m/min)

15 to 200 ipm(0.4 to 5.0 m/min)

142:1*

95:1

57:1

1/16 to 7/32 inch(1.6 to 5.6 mm)

1/16 to 3/32 inch(1.6 to 2.4 mm)

1/16 to 3/32 inch(1.6 to 2.4 mm)

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

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A-2INSTALLATION

CRUISER

A-2

GENERAL PHYSICAL DESCRIPTION

The CRUISER is a self propelled, modular platform

for performing submerged arc welds. A unique tubeand clamp design provides flexibility to mount the feed-

ing components in any position.

Wire is fed to the arc with the proven wire drive. All of

the drive rolls, nozzles, contact tips and wire straight-eners are common between the MaxSA wire drives

and the CRUISER wire drive. The wire drive rotatesabout 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 theelectrode stick-out and position of the wire in the joint.

The entire mast and arm structure separates from thebase for portability and mobility purposes.

Driving the tractor is a permanent magnet DC motorwith a 5 stage gear box built with all metal gears. A

high resolution encoder keeps the tractor speed con-

sistent even at slow speeds. The wheels are made ofa high temperature rubber specially bonded to an alu-minum core. Also mounted on the axle are guidewheels and a gear for operating on K396 track sec-

tions.

The tractor may be configured for 3 or 4 wheel opera-

tion. The flexible wheel configuration allows the tractorto be assembled in a manner for optimum balance

while aligning the wheels for the tracking of the joint.

All of the controls are housed in a light weight pendant

that connects to the tractor via an ArcLink cable. Thependant housing is fabricated from aluminum to resist

impacts and high temperatures.

GENERAL FUNCTIONAL DESCRIPTION

The CRUISER is a modular platform for submergedarc welding.

RECOMMENDED PROCESSES

SAW (AC, DC+, DC-) up to 1000 amps. Tiny Twin

PROCESS LIMITATIONS

The CRUISER does not support open arc proce-

dures.

EQUIPMENT LIMITATIONS

Curved extension nozzle limited to 3/16 wire. Inductance of the electrode and work cables may

affect arc performance. Do not coil excess cable. For robust digital communications, do not use more

than 200 feet of control cable. The CRUISER operates on 40 VDC only. There is no 115 VAC in the tractor.

The minimum turning radius of the CRUISER is 10feet when assembled with 3 wheels. The minimum turning radius of the CRUISER is 20

feet when assembled with 4 wheels. The rubber wheels are rated to 500F (260C) The laser pointer mounting bracket is not compatible

with the tiny twin nozzle or K148 nozzle.

RECOMMENDED POWER SOURCES

Power Wave AC/DC 1000

DESIGN FEATURES

Loaded with Standard Features

Arc Performance

The CRUISER and Power Wave AC/DC 1000combination provide for new levels of submerged arcproductivity.

User Controls

Light weight, hand-held pendant. Four memories for quick selection of common proce-

dures. Full sequence control for tailoring the weld from start

to end.

All welding controls located at the pendant, includingprogram selection. Laser pointer to aid in steering the CRUISER.

Wire Drive

Changeable gears for feeding small diameter wires athigh speed and large diameter wires at low speed.

High torque, permanent magnet DC motor withtachometer for accurate wire feed speed control.

Three roll wire straightener included. Uses standard Lincoln submerged arc contact noz-

zles.

Tractor and Frame

Configures to 3 or 4 wheels with patent pendingdesign, for the best tracking and balancing.

Permanent magnet DC motor with encoder forsteady, accurate travel speeds.

All steel gears for long life. Easily engaged travel clutch. Fully assembled for track use. High temperature rubber wheels for superior traction

and heat resistance up to 500F (260C). Heavy duty slides for adjusting the electrode position

in the joint.

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A-3INSTALLATION

CRUISER

A-3

LOCATION

Maintain clearance between parts at electrode poten-

tial and all other tractor components. Parts that are at

electrode potential are:

Wire

Wire spool

Wire straightener rolls

Brass Conduit bushing adapter

4 screw heads on back of the wire straighter

Feed plate and drive rolls

Contact nozzle assembly

Nozzle extensions

Contact Tip

Operate the CRUISER only on stable and dry sur-

faces.

Operating the tractor on inclined surfaces requires

adjusting and/or assembling the tractor differently thanshipped from the factory.

Do not submerge the tractor.

It is the responsibility of the user/builder/operator to

assemble the tractor to maintain safe electrical clear-ances and to be stable.

The tractor is rated for outdoor use (IP23S) with thewire reel enclosure installed.

Protect the CRUISER from preheat torches.

ELECTRIC SHOCK can kill.

Do not touch the wire drive,

drive rolls, nozzle, wire coil,electrode or wire drive motor

when welding output is ON. The tractor is an automatic

piece of equipment that maybe remotely controlled.

Turn the input power OFF at the disconnectswitch or fuse box before attempting to connect

or disconnect input power lines, output cables orcontrol cables.

Do not operate with covers, panels or guardsremoved.

Do not let the electrode or wire spool touch thetractor frame.

Only qualified personnel should perform thisinstallation.

Insulate yourself from the work and ground.

Always wear dry insulating gloves.

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

WARNING

MOVING PARTS can injure.

Keep away from moving parts.

Tractor parts may move sud-denly when the bolts are loos-ened.

All clamps and collars must be

secured before operating.

Configure the tractor for stable operation, with a

full and empty flux hopper and a full and emptyspool.

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

WARNING

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A-4INSTALLATION

CRUISER

A-4

GENERAL ASSEMBLY

Clamps

Tighten clamp bolts to 25 ft-lbs (34 Nm).

Use clamps with a key on horizontal tubes.

Collars

Tighten collar screw to 42 in-lbs (0.3 Nm)

Lift Bail

Tighten lift bail hardware to 24 in-lbs (0.17 Nm). Donot overtighten or the mast may become distorted.

Chain and Mast Anchor

The chain must be connected from the base to the

mast before lifting. Tighten all hardware as shown.


Improperly secured clampsand collars may shift, causing

parts at electrode potential to

contact the tractor frame orother components.

Only qualified personnel

should install, use or servicethis equipment.

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

WARNING

FALLING EQUIPMENT can causeinjury.

Lift only with equipment ofadequate capacity

Be sure the machine is stablewhen lifting.

Do not lift the machine if the lift bail is damaged.

Do not operate machine while suspended fromlift bail.

Failure to properly secure the clamps, collars,chains and lift bail may result in physical injury.

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

WARNING

FIGURE A.1 - CLAMPS

FIGURE A.2 - COLLARS

FIGURE A.3 - LIFT BALE

FIGURE A.4 - CHAIN AND MAST ANCHOR

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A-5INSTALLATION

CRUISER

A-5

OUTRIGGERS

The outriggers steer the CRUISER along a vertical

surface by driving it at a slight angle. Suggested offsetbetween the front and rear outriggers is (12.7mm).

Larger offsets increase the friction driving the CRUIS-

ER forward and may cause travel motor overcurrenterrors and rapid wheel wear.

When assembling the CRUISER, adjust the cross

slide to the middle position and position the wire in thejoint. Then assemble the front and rear outriggers, andmake fine adjustments to the wire position using the

cross slide.

The outriggers may be stacked to gain extra length.

Slide a T Nut (S28835) into the extrusion and theninsert a -20 bolt through the outrigger slots.

MANUAL STEERING MECHANISM,ASSEMBLY

As shipped from the factory, the manual steeringmechanism is assembled with a guide wheel for track-

ing in a butt joint. The guide wheel may be replacedwith a rubber wheel for manual steering.

FIGURE A.5 - OUTRIGGERS

FIGURE A.6 - OUTRIGGERS EXTENSION

FIGURE A.7 - MANUAL STEERING MECHANISM

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A-6INSTALLATION

CRUISER

A-6

MANUAL STEERING MECHANISM,ADJUSTMENT

To steer the CRUISER to the Right:

Loosen bolt BTighten bolt A to set the wheel angle.

Snug bolt B

To steer the CRUISER to the Left:

Loosen bolt ATighten bolt B to set the wheel angle

Snug bolt A

CROSS SLIDE

Each slide has 4 (102mm) of travel.

When assembling the CRUISER, verify that no com-

ponents at electrode potential contact the framethroughout the entire travel distance of the slides.

The slides may be disassembled and then positioned

relative to each other.

WIRE REEL SPINDLE

Position the wire reel spindle to prevent the reeland electrode from contacting the tractor frame and

base. The wire reel spindle must be horizontal or oriented

upwards.

FIGURE A.8 - ADJUSTMENT

FIGURE A.9 - LOAD LIMITS

FIGURE A.10 - SEVERAL POSSIBLE SLIDE CONFIGURATIONS

FIGURE A.11 - WIRE REEL SPINDLE

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A-7INSTALLATION

CRUISER

A-7

WIRE REEL ENCLOSURE ASSEMBLY

1. Determine the angular orientation of the wire reel

enclosure relative to the spindle clamp. To changethe angle of the enclosure, remove the 6 bolts

securing the enclosure back to the mounting brack-et using a 7/16 wrench. Reassemble at the desireangle, keep the gasket centered relative to the

enclosure back. Provisions are made to rotate theenclosure in 30 increments.

2. Unscrew the spindle brake and remove the spindlebrake parts and the spindle.

3. Remove two of the bolts from the spindle assem-bly using a 1/4 hex key. Assemble the enclosure

back to the spindle assembly and tighten the bolts.

FIGURE A.11a - ENCLOSURE ASSEMBLY

FIGURE A.11b - ENCLUSURE MOUNTING

BRACKET

GASKET

ENCLOSURE

BACK

HARDWARE

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A-8INSTALLATION

CRUISER

A-8

4. Reassemble the spindle parts as shown.

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

assembly. Use a 7/16 wrench to loosen andtighten the hardware.

6. Thread the conduit into the brass fitting on the

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

7. When assembling the enclosure cover to the

enclosure back, verify the cover is evenly seated

all the way around.

FIGURE A.11c - SPINDLE PARTS

FIGURE A.11d - CONDUIT, BRASS FITTING, BOOT

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A-9INSTALLATION

CRUISER

A-9

TAKE-OFF ARM

Position the take off arm to prevent contact to thereel and electrode.

Route the electrode through the conduit from thetake off arm to the wire drive.

FIGURE A.12 - TAKE-OFF ARM

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A-10INSTALLATION

CRUISER

A-10

WIRE STRAIGHTENER ADJUSTMENT

The wire straightener controls the amount of cast (orcurve) in the wire. Excessive cast may effect align-

ment of the wire in the joint. Too little cast may resultin insufficient wire contact in the contact tip.

To adjust the wire straightener:

1. Turn off power at the welding power source.

2. Loosen the two screws holding the wire straighten-er to the feed plate with a hex key.

3. Position the straightener as desired to remove oradd cast to the wire.

4. Tighten the screws holding the wire straightener tothe feed plate.

5. Turn power on at the welding power source.

6. Feed wire through the straightener. Adjust the

amount of pressure on the wire with the straighten-er until the desired cast is achieved when the wire

exits the tip.

NOTE: A slight curvature to the wire helps to maintain

good electrical contact inside the contact tip.

FEEDPLATE ROTATION

The feedplate of the wire drive may be rotated aboutthe drive roll axis. Depending upon how the tractor is

assembled, rotating the feed plate will change the tiltangle or the drag angle.

1. Turn off power at the welding power supply.

2. Loosen the set screw on the feedplate with a 5/16

hex key.3. Rotate the feedplate to the new position. Do not

allow surfaces at electrode potential to touch theframe, flux hopper, base or slides of the tractor.

4. Tighten the set screw to secure the feedplate.

5. As equipped from the factory, the tractor is set-upwith A as the inlet and B as the outlet. To make

B the inlet and A the outlet, see the SET-UPMENU.

FIGURE A.13 - WIRE STRAIGHTENER SCREWS

FIGURE A.14 - WIRE STRAIGHTENER

FIGURE A.15 - FEEDPLATE ROTATION

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A-11INSTALLATION

CRUISER

A-11

FLUX HOPPER

The flux hopper may be mounted on either a horizon-tal or vertical tube, or on the wire drive. For the best

flow of flux, keep the hose from the hopper to the noz-zle as vertical as possible.

CABLES

ArcLink Control Cables

ArcLink Control Cables are available in two forms:

K1543-xx series for most indoor or factory installa-

tions.

K2683-xx series for outdoor use or when the equip-

ment is frequently moved.

ArcLink/LincNet control cables are special high quality

cables for digital communication. The cables are cop-per 5 conductor cable in a SO-type rubber jacket.

There is one 20 gauge twisted pair for network com-munications. This pair has an impedance of approxi-

mately 120 ohms and a propagation delay per foot ofless than 2.1 nanoseconds. There are two 12 gaugeconductors that are used to supply 40VDC to the net-

work. The fifth wire is 18 gauge and is used as an elec-trode sense lead.

Use of non-standard cables may lead to system shut-

downs, poor arc starting and wire feeding problems.The control cables connect the power source to thewire feeder, and the wire feeder to other wire feeders.

Control cables may be connected end to end to extendtheir length. Use a maximum of 200 feet (61 m) of con-

trol cable between components.

FIGURE A.16 - VERTICAL TUBE MOUNTING

FIGURE A.17 - HORIZONTAL TUBE MOUNTING

FIGURE A.18 - WIRE DRIVE MOUNTING

FIGURE A.19 - ARCLINK CONTROL CABLES

A

BC

D

E

A

BC

D

E

Power Source Wire Feeder

Pin Function Pin Function

A ArcLink A ArcLink

B ArcLink B ArcLink

C 67 voltage sense C 67 voltage sense

D 40 VDC D 40 VDC

E Common E Common

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A-12INSTALLATION

CRUISER

A-12

CABLE CONNECTIONS

WELD CABLE SIZES

Tabulated below are copper cable sizes recommendedfor different currents and duty cycles. Lengths stipulat-

ed are the distance from the welder to work and backto the welder again. Cable sizes are increased for

greater lengths primarily for the purpose of minimizingcable drop.

** Tabled values are for operation at ambient temperatures of 40C and below. Applications above 40C mayrequire cables larger than recommended, or cables rated higher than 75C.

FIGURE A.20 - WIRE DRIVE MOUNTING

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

CABLE SIZES FOR COMBINED LENGTHS OF ELECTRODE AND WORK

CABLES

Amperes

Percent

Duty

Cycle0 to 50 Ft. 50 to 100 Ft. 100 to 150 Ft. 150 to 200 Ft. 200 to 250 Ft.

600

600

600

650

650

700

60

80

100

60

80

100

3/0

2-1/0

2-1/0

3/0

2-1/0

2-2/0

3/0

2-1/0

2-1/0

3/0

2-1/0

2-2/0

3/0

2-1/0

2-1/0

4/0

2-1/0

2-3/0

4/0

2-2/0

2-2/0

2-2/0

2-2/0

2-3/0

2-3/0

2-3/0

2-3/0

2-3/0

2-3/0

2-4/0

800800

1000

80100

80

3-1/02-3/0

2-4/0

3-1/02-3/0

2-4/0

3-1/02-3/0

2-4/0

2-3/02-3/0

2-4/0

2-4/02-4/0

4-2/0

1000

1200

1200

1500

1500

100

80

100

80

100

3-3/0

3-4/0

4-4/0

4-4/0

5-4/0

3-3/0

3-4/0

4-4/0

4-4/0

5-4/0

3-3/0

3-4/0

4-4/0

4-4/0

5-4/0

3-3/0

3-4/0

4-4/0

4-4/0

5-4/0

3-3/0

3-4/0

4-4/0

4-4/0

5-4/0

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A-13INSTALLATION

CRUISER

A-13

SYSTEM SET-UP

FIGURE A.21 - SYSTEM SET-UP

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A-14INSTALLATION

CRUISER

A-14

BUTT JOINTS

Butt Joint, Track Welding

When operating on K396 track, change the wheelcalibration in the SET-UP menu to 5.65.

FIGURE A.22 - TRACK WELDING FRONT VIEW

FIGURE A.23 - TRACK WELDING REAR VIEW

FIGURE A.24 - TRACK WELDING TOP VIEW

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A-15INSTALLATION

CRUISER

A-15

FIGURE A.25 - BUTT JOINT, 3 WHEEL, MANUAL STEER FRONT VIEW

FIGURE A.26 - BUTT JOINT, 3 WHEEL, MANUAL STEER REAR VIEW

FIGURE A.27 - BUTT JOINT, 3 WHEEL, MANUAL STEER TOP VIEW

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A-16INSTALLATION

CRUISER

A-16

FIGURE A.28 - BUTT JOINT, 3 WHEEL, GUIDE WHEEL, FRONT VIEW

FIGURE A.29 - BUTT JOINT, 3 WHEEL, GUIDE WHEEL, REAR VIEW

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A-17INSTALLATION

CRUISER

A-17

FILLET JOINTS

Horizontal Fillet

Uses KP2721-2 curved nozzle extension (45).

FIGURE A.30 - BUTT JOINT, 3 WHEEL, GUIDE WHEEL, TOP VIEW

FIGURE A.31 - HORIZONTAL FILLET, CURVED NOZZLE EXTENTION, FRONT VIEW

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A-18INSTALLATION

CRUISER

A-18

FIGURE A.32 - HORIZONTAL FILLET, CURVED NOZZLE EXTENTION, REAR VIEW

FIGURE A.33 - HORIZONTAL FILLET, CURVED NOZZLE EXTENTION, TOP VIEW

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A-19INSTALLATION

CRUISER

A-19

HORIZONTAL FILLET

Uses KP2721-1 straight nozzle extensions.

FIGURE A.34 - HORIZONTAL FILLET, STRAIGHT NOZZLE EXTENTION, FRONT VIEW

FIGURE A.35 - HORIZONTAL FILLET, STRAIGHT NOZZLE EXTENTION, REAR VIEW

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FIGURE A.37 - HORIZONTAL FILLET TOP VIEW

A-20INSTALLATION

CRUISER

A-20

FIGURE A.36 - HORIZONTAL FILLET, STRAIGHT NOZZLE EXTENTION, TOP VIEW

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A-21INSTALLATION

CRUISER

A-21

FLAT FILLET (TROUGH)

FIGURE A.38 - FLAT FILLET (TROUGH) FRONT VIEW

FIGURE A.39 - FLAT FILLET (TROUGH) REAR VIEW

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A-22INSTALLATION

CRUISER

A-22

FLAT FILLET (TROUGH) (CONTINUED)

FIGURE A.40 - FLAT FILLET TOP VIEW

FIGURE A.41 - FLAT FILLET TOP VIEW

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A-23INSTALLATION

CRUISER

A-23

PIPE WELDING

Internal inner diameter welds. The CRUISER may

be assembled to fit inside pipes with a 44 (1.1m) innerdiameter.

FIGURE A.42 - PIPE WELDING FRONT VIEW

FIGURE A.43 - PIPE WELDING REAR VIEW

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A-24INSTALLATION

CRUISER

A-24

PIPE WELDING (CONTINUED)

FIGURE A.45 - PIPE WELDING TOP VIEW

FIGURE A.44 - PIPE WELDING TOP VIEW

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A-25INSTALLATION

CRUISER

A-25

BASE DIMENSIONS ONLY

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B-1OPERATIONB-1

SAFETY PRECAUTIONS, OPERA-

TION

The serviceability of a product or structure utilizingthe welding programs is and must be the soleresponsibility of the builder / user. Many variablesbeyond the control of The Lincoln ElectricCompany affect the results obtained in applyingthese programs. These variables include, but arenot limited to, welding procedure, plate chemistryand temperature, weldment design, fabricationmethods and service requirements. The availablerange of a welding program may not be suitable forall applications, and the build / user is and must besolely responsible for welding program selection.

CRUISER


Turn the input power OFF at

the disconnect switch beforeworking on this equipment.

Do not touch electrically hotparts.

Only qualified personnel should install, use orservice this equipment.

Do not allow parts at electrode potential to touchthe tractor frame, cress slides, base flux hopper

or other parts.

Disengaging the clutch does not stop the weld-

ing arc.

Always wear dry insulating gloves.

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

WARNINGMOVING PARTS can injure.

Do not leave the tractor unat-tended while it is welding or

traveling.

Electrode reel, drive rolls and

wire straightener rolls turnduring welding or inching.

Keep gloved hands away from rotating parts.

Keep away from pinch points.

Do not place the tractor on inclined surfaces with

the clutch disengaged.

Only qualified personnel should install, use or

service this equipment.

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

WARNING

GRAPHIC SYMBOLS

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

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

dant.

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

switch in the MANUAL travel position.

MOVING THE TRACTOR

The tractor will not travel unless the clutch is engaged.To engage the clutch, rotate the handle upwards. Todisengage the clutch, rotate the handle to the 3 oclock

position.

The travel speed is adjustable from 7 to 100 in/min

(1.78 to 2.54 m/min). From 7 to 20 in/min, the travelspeed may be set in 0.5 inch/min increments. Above

20 in/min, the travel speed adjusts at 1.0 inch/minincrements.

To drive the tractor without welding:

B-2OPERATIONB-2

CRUISER

FIGURE B.1 - PENDANT CONTROLS

FIGURE B.2 - ENGAGE THE CLUTCH

FIGURE B.4 - JOB BUTTON, TOGGLE SWITCH

FIGURE B.3 - TRAVEL DIRECTION

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B-3OPERATIONB-3

LASER POINTER

Laser pointer is used to aid in guiding the CRUISER.The laser pointer mounts to the nozzle or nozzle exten-

sions. Align the wire in the joint, then position the laserpointer approximately 3 (76mm) in front of the wire,also pointing into the joint.

Turn the laser off when not welding.

TOUCH SENSE

ELECTRIC SHOCK can kill. 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.------------------------------------------------------------------------

The touch sense option, when enabled, allows theoperator to feed the wire forward until it touches theworkpiece. When contact to the work is made, the wire

will stop.

If the touch sense option is disabled, the wire is coldduring the Feed Forward time. It will not stop when it

touches the work.

POWER-UP SEQUENCEWhen power is first applied to the CRUISER the

MODE SELECT Display reads CRUISER

Initializing.... Once the Power Wave AC/DC has ini-

tialized (20 to 60 seconds) a lamp test is performed.

All discrete LEDs, seven segment displays andalpha numeric displays will be turned ON for 2 sec-onds.

After 2 seconds all displays are turned OFF againand the MSP Display will show:

After initialization is complete, the MSP Display willshow the weld mode. The upper displays will show the

parameters that were selected when the machine was

last powered down and the WELD MODE Indicator willbe ON.

CRUISER

Class II laser radiation present. Do not stareinto laser beam or view directly with optical

instruments.

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

CAUTION

FIGURE B.5 - MSP DISPLAY

FIGURE B.6 - WELD MODE INDICATOR

WARNING

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B-4OPERATIONB-4

WIRE FEEDER SETUP

Use the FEED FORWARD pushbutton to insert wireinto the feed mechanism.

While pressing either the FEED FORWARD or FEEDREVERSE pushbutton the MSP Display will read as

shown and the preset wire feed speed will be displayedon the left (AMPS/WFS) display.

The feed speed can be changed by adjusting the con-trol knob below the display while pressing either but-ton. Use FEED REVERSE to retract the wire from thefeed mechanism. FEED FORWARD feeds the wire

downward toward the work piece.

The CRUISER has an option in the Setup Menu(P.15) to enable the Touch Sense circuitry. See the

Setup Menu. When P.15 is enabled and the FEEDFORWARD button is pressed, the MSP Display will

read:

WARNING: This Hot Feed feature enables the

output of the power source and there is voltage onthe wire while feeding down. Avoid touching any

exposed parts as defined in the SAFETY PRECAU-TIONS.

CHANGING AND SETTING WELD MODES

To select a weld mode, press the WELD MODESELECTOR button until the WELD MODE indicator

comes ON (it may already be lit by default at powerup). Turn the control knob to select the desired mode.

After about 1 second, the parameters for the newmode will be displayed. These parameters can be

adjusted with the control knobs below each display.

NOTE: CC Modes will show AMPS in the upper leftdisplay. CV Modes will show wire feed speed

and the WFS indicator will be lit.

FREQUENCY

Press the WELD MODE selector until the FREQUEN-

CY/ BALANCE indicator comes ON and the MSPDisplay reads Frequency. If the selected mode allows

for frequency adjustment, the Control Knob can beused to select the desired frequency between 10 and100hz.

Frequency adjustment can be used to fine tune stabil-ity of imbalanced waveforms and multiple arc system.

CRUISER


Prior to inserting the wire, dis-able Touch Sense (P.15 in

the Setup Menu).

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

WARNING

FIGURE B.7 - FEED SPEED DISPLAY

FIGURE B.8 - HOT FEED FEATURE

FIGURE B.9 - SETTING WELD MODES

FIGURE B.10 - FREQUENCY

Use Frequence to fine tune stability of imbalance

waveforms and multiple arc systems

Decrease Increase

1000

- 1000

600

- 600

0

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B-5OPERATIONB-5

BALANCE ADJUST

Press the WELD MODE selector until the MSP Displayreads Balance. If the selected mode allows for bal-

ance adjustment, the Control Knob can be used toselect the desired wave balance through a range of

25% to 75%.

Adjusting the Balance (the ratio between Positive and

Negative half cycle on time) changes the depositionfor more efficient welding.

OFFSET ADJUST

Press the WELD MODE selector until the MSP Display

reads Offset. If the selected mode allows for offsetadjustment, the Control Knob can be used to select the

desired offset. The amount of offset allowed is deter-mined by the selected weld mode.

Independent control of the Positive and Negativecycles allows for more precise control of penetration

and deposition.

WELD SEQUENCE

The weld sequence defines the weld procedure frombeginning to end. All adjustments are made through

the user interface.

START OPTIONSThe delay, strike, start and upslope parameters areused at the beginning of the weld sequence to estab-lish a stable arc and provide a smooth transition to the

welding parameters. They are described in the follow-ing:

ARC DELAY inhibits the wire feed for up to 5 sec-onds to provide an accurate weld start point.

Typically used in multi-arc systems.

STRIKE settings are valid from the beginning of thesequence (Start) until the arc is established. They

control run-in (speed at which the wire approachesthe workpiece) and provide the power to establishthe arc. Typically output levels are increased, and

WFS is reduced during the strike portion of the weldsequence.

START values allow the arc to become stabilizedonce it is established. Extended start times or

improperly set parameters can result in poor starting.

UPSLOPE TIME determines the amount of time it

takes to ramp from the start parameters to the weldparameters. The transition is linear and may be up or

down depending on the relationship between the

start and weld settings.

CRUISER

FIGURE B.11 - BALANCE ADJUST

500

-500

0

-1000

1000

Nominal Balance

Increased BalanceMore PenetrationLess Deposition Decreased Balance

Less PenetrationMore Deposition

FIGURE B.12 - OFFSET ADJUST

500

-500

0

-1000

1000

Nominal Offset

Positive OffsetMore PenetrationLess Deposition

Negative OffsetLess PenetrationMore Deposition

FIGURE B.13 - WELD SEQUENCE

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B-6OPERATIONB-6

START OPTIONS OPERATION

Pressing the Arc Start/End Options pushbutton willilluminate the START OPTIONS LED and the Arc

Delay Time parameter will show on the MSP Display.

Use the Mode Select Panel Control to select thedesired delay time. Press the Weld Mode Selector to

exit the Start parameters. Repeated pressing of theArc Start/End Options pushbutton will scroll throughthe parameters. Turning the Mode Select Panel

Control, while on a parameter will change its value.

When a Start Option is set to a value other than OFF,the START OPTIONS LED will blink synchronous withthe WFS or Amps and/or the Volts LED located on the

Dual Display Panel prompting the user to enter theseparameters. The parameters that can be set by theuser in the START OPTIONS will be as follows:

ARC DELAY TIME

STRIKE WFSSTRIKE TIMESTART WFS/AMPS

START VOLTSSTART TIME

UPSLOPE TIME

END OPTIONS

The downslope, crater, and burnback parameters are

used to define the end of the weld sequence. They aredefined in the following:

DOWNSLOPE determines the amount of time ittakes to ramp from the weld parameters to the crater

parameters. The transition is linear and may be up ordown depending on the relationship between theweld and crater settings.

CRATER parameters are typically used to fill thecrater at the end of the weld and include both timeand output settings.

BURNBACK defines the amount of time the outputremains on after the wire has stopped. This feature

is used to prevent the wire from sticking in the weldpuddle and to condition the end of the wire for thenext weld. A burnback time of 0.4 second is sufficient

in most applications.

RESTRIKE TIME determines how long the systemwill try to re-establish the arc in the event of a poorstart or if the arc goes out for any reason (short cir-

cuit or open circuit). During restrike, the WFS andoutputs are driven in an attempt to re-establish the

arc.

A restrike time of 1 to 2 seconds is sufficient

in most applications.

A restrike time of 0 seconds allows therestrike function to continue indefinitely.

END OPTIONS OPERATION

Pressing the Arc Start/End Options pushbutton after

scrolling through the Start Options will illuminate theEND OPTIONS LED and the Downslope Time para-

meter will show on the MSP Display.

Use the Mode Select Panel Control to select the

desired delay time. Press the Weld Mode Selector toexit the End parameters. Repeated pressing of the Arc

Start/End Options pushbutton will toggle through theparameters. Turning the Mode Select Panel Control

while on a parameter will change its value. When the

Crater Time is set to a value other than OFF, the ENDOPTIONS LED will blink synchronous with the WFS or

Amps LED (depending on CC or CV Weld Modes) andwith the Volts LED located on the Dual Display Panel

prompting the user to enter these parameters. Theparameters that can be set by the user in the END

OPTIONS will be as follows:

DOWNSLOPE TIME

CRATER WFS/AMPSCRATER VOLTS

CRATER TIMEBURNBACK TIME

RESTRIKE TIME

CRUISER

FIGURE B.14 - START OPTIONS OPERATION

FIGURE B.15 - END OPTIONS OPERATION

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B-7OPERATIONB-7

MEMORIES

The CRUISER has 4 memories. Each memory

stores :

Weld Mode

Amperage (or WFS) Voltage

Travel Speed Frequency

Balance DC Offset Arc Start Options

Arc End Options

Recall a memory with memory buttons

To recall a memory, press one of the four memory but-

tons. The memory is recalled when the button isreleased. Do not hold the button for more than two sec-

onds.

Save a memory with memory buttons

To save a memory, press and hold the desired memo-ry button for two seconds. When the button is initially

pressed, the corresponding LED will illuminate. Aftertwo seconds, the LED will turn off. Do not hold the but-

ton for more than 5 seconds when saving a user mem-ory.

Note that memories may be locked in the set-up menuto prevent accidental overwrite of the memories. If anattempt is made to save a memory when memory sav-

ing is locked, the message "Memory save is Disabled!"will appear briefly in the MSP4 display.

LIMITS

Limits allow the welder to adjust the welding procedureonly within a defined range.

Each memory may have a different set of limits. Forexample, memory 1 may limit the WFS to 100 through

120 in/min, and memory 2 may limit the WFS to 140through 160 in/min, while memory 3 may have no WFS

limits.

Parameters are constrained by machine limits, or by

setting memory limits. When memory limits areenabled, the parameter will flash whenever an attempt

is made to exceed the memory limit value. The para-meter will not flash if an attempt is made to exceed the

machine limit.Limits may be set for:

Wire Feed Speed

VoltageAmperageTravel Speed

FrequencyBalance

DC OffsetArc Start Options

Arc End Options

Weld modes cannot be selected through the LimitsSetup menu, and must be chosen and saved to mem-

ory before entering the Limits Setup Menu.

CRUISER

FIGURE B.16 - MEMORIES

FIGURE B.17 - LIMITS

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B-8OPERATIONB-8

To set limits, press the desired memory button 1-8 andhold for 5 seconds. Release the memory button whenthe LED begins to blink rapidly and the MSP4 displays

"Memory X Set Limits" as shown below.

SETUP will illuminate on the MSP4 panel and the dis-play will show the following:

Four items show on the MSP4 panel.

Memory Value High Limit

Low Limit Parameter Name

One of these items will flash to indicate which item willchange when the MSP4 encoder is rotated. Press the

right button on the MSP4 panel to select the item tochange.

The Limits Setup menu shows a list of all parametersavailable for the weld mode stored in the memory cho-sen

To lock a parameter to a specific value that cannot

be changed, set the high and low limits to the samevalue.

The memory value must always be less than or equalto the high limit, and greater than or equal to the low

limit.

After setting limits, press the memory button with the

flashing LED. The MSP4 will ask to save or discard thelimit changes just made. Press the left MSP4 for button(YES) to save and enable the limits and exit. Press the

right MSP4 button (NO) to exit and leave limitsunchanged.

ENABLING/DISABLING LIMITS

Limits for each memory may be enabled or disabled by

pressing and holding the appropriate memory buttonfor 10 seconds. Release the memory button when theMSP4 display shows the following:

CRUISER

FIGURE B.18 - MEMORY SET LIMITS

FIGURE B.19 - MEMORY SET LIMIT DISPLAYLOWLIMIT

PARAMETERNAME

MEMORYVALUE

HIGHLIMIT

FIGURE B.20 - MSP4 PANEL

FIGURE B.21 - ENABLING LIMITS

FIGURE B.22 - ENABLE/DISABLE LIMITS

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B-9OPERATIONB-9

SETUP will light and the MSP4 displays the following:

Press the left MSP4 button (YES) to enable limits orthe right MSP4 button (NO) to disable limits. Disabling

limits does not change any limits values that may havebeen previously set.

CRUISER

FIGURE B.23 - ENABLE/DISABLE LIMITSDISPLAY

1 2 3 4 5 6 7 8ON

OFF8 7 6 5 4 3 2 1

OFF

ON

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

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

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B-10OPERATIONB-10

SET-UP FEATURES MENU

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

To access the set-up menu, press the right and left buttons of the MSP4 panel simultaneously. Note that the set-up menu cannot be accessed if the system is welding, or if there is a fault (The status LED is not solid green).

Change the value of the blinking parameter by rotating the SET knob.

To exit the set-up menu at any time, press the right and left buttons of the MSP4 panel simultaneously. Alternately,1 minute of inactivity will also exit the set-up menu.

CRUISER

PARAMETERP.1 through P.99

P.101 through P.199P.501 through P.599

DEFINITIONUnsecured Parameters (always adjustable)

Diagnostic Parameters (always read only)Secured Parameters (only accessible with Weld Manager)

PARAMETER DEFINITION

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

P.1 WFS unitsMetric = m/min wire feed speed units

English = in/min wire feed speed units (default)

P.2 Arc Display ModeAmps = The left display shows Amperage while welding. (default)

WFS = The left display shows Wire Feed Speed while welding.

P.3 Display OptionsThis setup parameter was previously named "Display Energy"

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

This option selects the information displayed on the alphanumeric displays while welding. Notall 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 sourcemay 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 OptionsThis menu is used to change the travel options for a travel carriage, including wheel size and

starting and ending functions. Press the right MSP4 button to enter the Travel Options menuand rotate the encoder to select either wheel size, starting or ending options. Press the right

MSP4 button to select the option. Press the left MSP4 button to set the value and exit. Rotate

the encoder to select other options, or press the left MSP4 button to exit the menu.Travel Start Options

Start Button = Travel begins with the start button (default)Arc Strike = Travel beings with arc strike.

Travel End Options

Stop Button = Travel ends with the stop button. (default)

Arc Out = Travel ends when the arc extinguishes.Wheel Size

default value = 6.0

wheel size for track welding = 5.65range = 3.0 to 12.0

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B-11OPERATIONB-11

CRUISER


P.14 Reset Consumable WeightThis parameter only appears with systems using Production Monitoring.

Use this parameter to reset the initial weight of the consumable package.

P.15 Cold-Inch Touch Sense OptionEnabled = touch sense is active when inching wire forward.Disabled = touch sense is inactive when inching wire forward. (default)

P.21 Shutdown 2 Function SelectThis option allows selection of the Shutdown 2 input function on the controlbox.

Normal Shutdown = The Shutdown 2 input functions as a standard shut-down 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.23Trigger Fan-OutFor Sub-Arc Lead Arc machines only. Allows the Lead Arc User Interface

to control all machine triggers in a multi-arc system.No = Only the machine connected to the User Interface can be triggered on

and off (default).Yes = All machines in the system can be triggered on and off simultane-ously.

P.18 Wire Drive Gear Ratio.Set this parameter to match the gear ratio of the wire drive.

142:1 (default)95:1

57:1

P.19 Wire Drive DirectionThe feed plate of the wire drive is reversible and the wire straightener and

the nozzle assembly may be swapped. The feed plate can feed from A(inlet ) to B (outlet); or B (inlet) to A (outlet).Set this parameter to match the Forward direction of wire feeding.

A B (Default)B A

P.80 Sense from Studs.Use this parameter for diagnostic purposes only. When power is cycled,P.80 is automatically reset to False.

False = Sensing for the electrode (67) and work (21) is determined by the

DIP switches of the system.True = Sensing for the electrode (67) and work (21) is measured at thestuds of the power source and the DIP switch settings are overridden.

P.99 Show Test ModesMany weld tables include special modes for testing and servicing the weld-

ing system. Set this parameter to YES to show all test modes.When the power source is turned off, the Show Test Modes parameter

automatically reverts back to NO.

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B-12OPERATIONB-12

CRUISER

P.100 View DiagnosticsDiagnostics are only used for servicing the Power Wave system.

Yes = Shows P.101 through P.500 in the SETUP menu.No = Only P.0 through P.100 are shown in the SETUP menu.

P.101 Event LogsPress the right MSP4 button to view the Event Logs. Rotate the encoder toselect the object to read and then press the right MSP4 button. Varioussoftware information will appear about key system events.

Press the left MSP4 button to exit.


P.102 Fatal LogsPress the right MSP4 button to view the Fatal Logs. Rotate the encoder toselect the module to read and then press the right MSP4 button. Various

software information will appear about critical module actions.Press the left MSP4 button to exit.

P.103 Software VersionPress the right MSP4 button to view the software loaded into each module(p.c. board). Rotate the encoder to select the module to read and thenpress the right MSP4 button. The panel will display the main software ver-

sion loaded into the module. Press the left MSP4 button to exit.

P.104 Hardware VersionPress the right MSP4 button to view the hardware version of each module(p.c. board). Rotate the encoder to select the module to read and then

press the right MSP4 button. The panel will display the main hardware ver-sion loaded into the module. Press the left MSP4 button to exit.

P.105 Welding SoftwarePress the right MSP4 button to view the welding software version inside the

power source. Press the left MSP4 button to exit.

P.106 Ethernet IP AddressPress the right MSP4 button to view the IP address of the Ethernet board.

If no Ethernet Board is installed, the display shows No Enet Found. Pressthe left MSP4 button to exit.

P.107 Power SourcePress the right MSP4 button to view the type of power source connected to

the control box. Press the left MSP4 button to exit.

P.500 Parameters that are P.500 and higher are only accessible with WeldManager. See Weld Manager documentation for details.

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C-1ACCESSORIESC-1

CRUISER

OPTIONAL KITS AND ACCESSORIES

DRIVE ROLL AND GUIDE TUBE KITS

K231 nozzles are rated up to 600 Amps

K148 nozzles are rated up to 1000 Amps

1

2

3

4

5

ITEM K# DESCRIPTION

1 K1733-5 Wire Straightener

KP1899-1 Drive Roll/ Guide Tube Kit , 3/32-7/32

2 KP1899-2 Drive Roll/ Guide Tube Kit, 1/16, 5/64, 3/32

KP1899-3 Drive Roll/ Guide Tube Kit , 035, 045, 052

KP1899-4 Drive Roll/ Guide Tube Kit , 045, 052 cored

K231-5/64 Contact Nozzle Assembly, 5/64 (2.0mm)


3 K231-1/8 Contact Nozzle Assembly, 1/8 (3.2mm)




4 KP2721-1 Nozzle Extension, 5

KP2721-2 Nozzle Extension, 45 Curved

T12929 Flux Hose ClampT11807 Nozzle Extension Insulator

KP1962-3B1 Contact Tip, 3/32


5 KP1962-4B1 Contact Tip, 5/32



K148A or Positive Contact Nozzle Assembly

K148B

K285 Concentric Flux Cone Assembly to use with

K148A or K148B

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C-2ACCESSORIESC-2

CRUISER

Accessories Included with the CRUISER:

Conduit Tubing, 5 feet (1.5 m)

5/32 600 Amp contact nozzle assembly5/32 contact tipNozzle extension, 5 inches long (127 mm)

Nozzle extension insulator

Nozzle extension, 45 CurvedFlux tubingFlux Hose Clamps

Wire Reel AssemblyWheels for track operationManually guide steering wheel (LT-7 like)

Front and Rear outriggersWire Reel Enclosure

Does not include a control cable.

K3090-1 Tube and clamp kit Includes: one 30aluminum splined tube;one 15 aluminum splinedtube; one 30 steel tube; 8clamp assemblies withkeys; 2 outriggerassemblies; hardware.

K3089-1 Cross Slide Assembly Includes: two slides with 4

inches of travel. (1 crossslide assembly includedwith each tractor.)

K1733-5 Wire Straightener Includes: A three roll wirestraightener withadjustable pressure. (1included with each tractor)

K396 Track Section Includes: a single sectionof 70 in (1.8m) of track.

K3070-1 Tiny Twin Kit for thetractor

Includes: 2ndspindle, driverolls, 57:1 gears.

K1543-xx ArcLink Control Cable Includes: 5 pin to 5 pintractor to power sourcecontrol cable. Cables may

be connected end-to-end tomake a longer cable.Connectors are blackanodized aluminum.

K2683-xx ArcLink Control Cable,Heavy Duty

Includes: 5 pin to 5 pintractor to power sourcecontrol cable. Cables maybe connected end-to-end tomake a longer cable.Female connector is abrass spin nut. Maleconnector is made fromstainless.

K1504-1 60 lb Coil Adapter Includes: one coil adapter

for use with 2 spindles.

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D-1MAINTENANCED-1

ROUTINE MAINTENANCE

Blow out the slides

PERIODIC MAINTENANCE

Check wire drive motor brushesLube gearbox for wire drive

CRUISER

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E-1TROUBLESHOOTINGE-1

CRUISER

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

CAUTION

This Troubleshooting Guide is provided to help youlocate and repair possible machine malfunctions.

Simply follow the three-step procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).

Look under the column labeled PROBLEM (SYMP-

TOMS). This column describes possible symptoms

that the machine may exhibit. Find the listing thatbest describes the symptom that the machine isexhibiting.

Step 2. POSSIBLE CAUSE.

The second column labeled POSSIBLE CAUSE lists

the obvious external possibilities that may contributeto the machine symptom.

Step 3. RECOMMENDED COURSE OF ACTION

This column provides a course of action for thePossible Cause, generally it states to contact your

local Lincoln Authorized Field Service Facility.

If you do not understand or are unable to perform theRecommended Course of Action safely, contact your

local Lincoln Authorized Field Service Facility.

HOW TO USE TROUBLESHOOTING GUIDE

Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.Unauthorized repairs performed on this equipment may result in danger to the technician and

machine operator and will invalidate your factory warranty. For your safety and to avoid ElectricalShock, please observe all safety notes and precautions detailed throughout this manual.

__________________________________________________________________________

WARNING

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CRUISER


CAUTION

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS(SYMPTOMS)

POSSIBLECAUSE

RECOMMENDEDCOURSE OF ACTION

If all recommended possible areasof misadjustment have been

checked and the problem persists,Contact your local Lincoln

Authorized Field Service Facility.

Frequency and Balance do not

appear on the display.

Error 215

1. Verify a AC square wave weldmode has been selected.

1. Check that all of the DIP switch-

es on the travel drive board andthe wire drive board are in the

OFF position.

A travel motor overload occurs.(Error 81)

1. Verify the Cruiser rolls freely

when the clutch is disengaged.2. Check for excessive loads

caused by dragging long cables.

3. When using the outriggers tosteer the Cruiser, set the offset

between the front and rear out-riggers at 0.5 (12.7mm).

4. Verify the front wheels are per-fectly straight.

The wire feeder does not feed wireand the drive rolls do not spin.

1. Verify the power source isturned on.

2. Verify the circuit breaker for thewire feeder power (on the power

source) has not tripped.3. Verify power is being supplied

to the wire feeder.4. Check that any equipment con-

nected to the external shut-off

inputs has not faulted.

A wire drive motor overload occurs.

(Error 81)1. Examine the contact tip for wear

and proper size. Replace as

necessary.2. Verify the correct drive rolls and

inner wire guide are installed inthe wire drive.

3. Do not use more idle roll pres-sure than necessary. Check forproper setting.

4. Verify that the wire pulls easilythrough the take-off arm bushing

and conduit.5. Check that the wire straightener

is not exerting excessive load onthe wire.

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

95:1 or 142:1

7. If using 95:1 gear ratio, switch to142:1.

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CRUISER


CAUTION

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS(SYMPTOMS)

POSSIBLE AREAS OFMISADJUSTMENTS(S)

RECOMMENDEDCOURSE OF ACTION

If all recommended possible areas

of misadjustment have beenchecked and the problem persists,

Contact your local LincolnAuthorized Field Service Facility.

When the welding arc is activated,the drive rolls spin but no arc is pre-

sent.

The arc goes to full output.

The Cruiser welds for a short peri-od, then the arc goes out, the wire

stops, travel continues, and noerror codes are displayed on thependant.

1. Check all electrode and work

connections.

1. Check for loose or damaged

work and electrode sense leads.

1. Verify work sense lead is making

a good connection and there isno damage to the lead.

2. Check the electrode sense leadat the Cruiser and make sure it isa good connection.

The wire drive feeds wire in the

wrong direction.

The wire drive speed is incorrect.

1. Change P19 wire feed directionparameter in the Set-Up menu.

1. Verify the gear ratio of the wiredrive and P18 match.

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F-1WIRING DIAGRAMF-1

CRUISERNOTE:Thisdiagrami

sforrefer

enceonly.

Itmaynotbeaccurateforallmachinescoveredbythismanual.Thespecificdiagramf

oraparticularcodeispastedinsidethe

machineononeoftheenclosure

panels.

Ifthediagrami

sillegible,writetotheServiceDepartmentforarepla

cement.Givetheequipmentcodenum

ber.

ENHANCED DIAGRAM

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WARNING

AVISO DEPRECAUCION

ATTENTION

WARNUNG

ATENO

Spanish

French

German

Portuguese

Japanese

Chinese

Korean

Arabic

READ AND UNDERSTAND THE MANUFACTURERS INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BEUSED AND FOLLOW YOUR EMPLOYERS SAFETY PRACTICES.

SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOSCONSUMIBLES 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 AETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-STELLERS. DIE UNFALLVERHTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

Do not touch electrically live parts orelectrode with skin o

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