Lincoln Electric Cruiser K3048-1 Operator's Manual
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Lincoln Electric Cruiser K3048-1 Operator's Manual

Lincoln Electric Cruiser K3048-1 Operator's Manual

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Operator's Manual
CRUISER
Register your machine:
www.lincolnelectric.com/register
Authorized Service and Distributor Locator:
www.lincolnelectric.com/locator
Save for future reference
Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)
IM10098-B
| Issue D ate Sept-14
© Lincoln Global, Inc. All Rights Reserved.
™
For use with machines having Code Numbers:
11767, 11910, 11947

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Summary of Contents for Lincoln Electric Cruiser K3048-1

  • Page 1 Operator’s Manual ™ CRUISER For use with machines having Code Numbers: 11767, 11910, 11947 Register your machine: www.lincolnelectric.com/register Authorized Service and Distributor Locator: www.lincolnelectric.com/locator Save for future reference Date Purchased Code: (ex: 10859) Serial: (ex: U1060512345) IM10098-B | Issue D ate Sept-14 ©...
  • Page 2 THANK YOU FOR SELECTING A QUALITY PRODUCT BY KEEP YOUR HEAD OUT OF THE FUMES. DON’T get too close to the arc. LINCOLN ELEC TRIC. Use corrective lenses if necessary to stay a reasonable distance away from the arc. READ and obey the Safety Data PLEASE EXAMINE CARTON AND EQUIPMENT FOR Sheet (SDS) and the warning label DAMAGE IMMEDIATELY...
  • Page 3 W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 2.d. All welders should use the following procedures in order to 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
  • Page 4 SAFETY ELECTRIC SHOCK ARC RAYS CAN BURN. CAN KILL. 3.a. The electrode and work (or ground) circuits are 4.a. Use a shield with the proper filter and cover plates to protect your electrically “hot” when the welder is on. Do eyes from sparks and the rays of the arc when welding or not touch these “hot”...
  • Page 5 SAFETY WELDING AND CUTTING CYLINDER MAY EXPLODE IF SPARKS CAN CAUSE DAMAGED. FIRE OR EXPLOSION. 7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used 6.a. Remove fire hazards from the welding area. If and properly operating regulators designed for this is not possible, cover them to prevent the welding sparks the gas and pressure used.

  • Page 6: Table Of Contents

    TABLE OF CONTENTS Page Installation........................Section A Technical Specifications.......................A-1 General Physical Description ....................A-2 General Functional Description ....................A-2 Recommended Processes ....................A-2 Process Limitations ......................A-2 Equipment Limitations ......................A-2 Recommended Power Sources....................A-2 Design Features ........................A-2 Location..........................A-3 General Assembly ........................A-4 Outriggers, Manual Steering Mechanism, Assembly ............A-5 Manual Steering Mechanism, Adjustment................A-6 Cross Slide ...........................A-6 Wire Reel Spindle.........................A-6...
  • Page 7 CRUISER INSTALLATION TECHNICAL SPECIFICATIONS - CRUISER ™ K-3048-1 Wire Feeders - Input Voltage and Current VOLTAGE 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...

  • Page 8: Installation

    CRUISER INSTALLATION GENERAL PHYSICAL DESCRIPTION EQUIPMENT LIMITATIONS • Curved extension nozzle limited to 3/16” wire. The CRUISER™ is a self propelled, modular platform • Inductance of the electrode and work cables may for performing submerged arc welds. A unique tube affect arc performance.
  • Page 9 CRUISER INSTALLATION • Contact nozzle assembly • Nozzle extensions WARNING • Contact Tip ELECTRIC SHOCK can kill. Operate the CRUISER™ only on stable and dry sur- • Do not touch the wire drive, drive rolls, nozzle, wire coil, faces. electrode or wire drive motor Operating the tractor on inclined surfaces requires when welding output is ON.

  • Page 10: General Assembly

    CRUISER INSTALLATION GENERAL ASSEMBLY Collars • Tighten collar screw to 42 in-lbs (0.3 Nm) WARNING FIGURE A.2 - COLLARS ELECTRIC SHOCK can kill. • Improperly secured clamps and collars may shift, causing parts at electrode potential to contact the tractor frame or other components.
  • Page 11 CRUISER INSTALLATION See Figure A.7. To steer the front wheel to the left, loosen bolt A and tighten bolt B to set the angle, then FRONT WHEELS In almost all configurations the front wheels must snug bolt A. remain parallel with the Cruiser base and rear wheels To steer the front wheel to the right, loosen bolt B and (See Figure A.5).
  • Page 12 CRUISER INSTALLATION OUTRIGGERS MANUAL STEERING MECHANISM, The outriggers “steer” the CRUISER™ along a vertical ASSEMBLY surface by driving it at a slight angle. Suggested offset As shipped from the factory, the manual steering Larger offsets increase the friction driving the CRUIS- between the front and rear outriggers is ½”...

  • Page 13: Manual Steering Mechanism, Adjustment

    CRUISER INSTALLATION MANUAL STEERING MECHANISM, FIGURE A.13 - LOAD LIMITS ADJUSTMENT To steer the CRUISER™ to the Right: Loosen bolt B Tighten bolt A to set the wheel angle. Snug bolt B To steer the CRUISER™ to the Left: Loosen bolt A Tighten bolt B to set the wheel angle Snug bolt A FIGURE A.11 - ADJUSTMENT...
  • Page 14 CRUISER INSTALLATION WIRE REEL ENCLOSURE ASSEMBLY- WIRE REEL ENCLOSURE ASSEMBLY- FOR CODES BELOW 11947 FOR CODE 11947 AND ABOVE 1. Determine the angular orientation of the wire reel 1. Remove the #10 screws and lockwashers from the enclosure relative to the spindle clamp. To change spindle assembly using a 5/32"...
  • Page 15 CRUISER INSTALLATION 4. Reassemble the spindle parts as shown (all codes) FIGURE A.14d - SPINDLE PARTS 5. If required, swap the position of the ball bushing assembly. Use a 7/16” wrench to loosen and tight- en the hardware. 6. Thread the conduit into the brass fitting on the ball bushing assembly.

  • Page 16: Take-Off Arm

    CRUISER INSTALLATION TAKE-OFF ARM • Position the take off arm to prevent contact to the reel and electrode. • Route the electrode through the conduit from the take off arm to the wire drive. FIGURE A.15 - TAKE-OFF ARM A 10...

  • Page 17: Wire Straightener Adjustment

    CRUISER INSTALLATION WIRE STRAIGHTENER ADJUSTMENT FEEDPLATE ROTATION The wire straightener controls the amount of cast (or The feedplate of the wire drive may be rotated about “curve”) in the wire. Excessive cast may effect align- the drive roll axis. Depending upon how the tractor is ment of the wire in the joint.

  • Page 18: Flux Hopper Cables

    CRUISER INSTALLATION FLUX HOPPER CABLES The flux hopper may be mounted on either a horizontal ArcLink Control Cables or vertical tube, or on the wire drive. For the best flow ArcLink Control Cables are available in two forms: of flux, keep the hose from the hopper to the nozzle as vertical as possible.
  • Page 19 CRUISER INSTALLATION CABLE CONNECTIONS FIGURE A.23 - WIRE DRIVE MOUNTING WELD CABLE SIZES Tabulated below are copper cable sizes recommended for different currents and duty cycles. Lengths stipulat- ed are the distance from the welder to work and back to the welder again. Cable sizes are increased for greater lengths primarily for the purpose of minimizing cable drop.

  • Page 20: System Set-Up

    CRUISER INSTALLATION SYSTEM SET-UP FIGURE A.24 - SYSTEM SET-UP A 14...

  • Page 21: Butt Joints

    CRUISER INSTALLATION BUTT JOINTS Butt Joint, Track Welding • When operating on K396 track, change the wheel calibration in the SET-UP menu to 5.65”. FIGURE A.25 - TRACK WELDING FRONT VIEW FIGURE A.26 - TRACK WELDING REAR VIEW FIGURE A.27 - TRACK WELDING TOP VIEW A 15...
  • Page 22 CRUISER INSTALLATION FIGURE A.28 - BUTT JOINT, 3 WHEEL, MANUAL STEER FRONT VIEW FIGURE A.29 - BUTT JOINT, 3 WHEEL, MANUAL STEER REAR VIEW A 16...
  • Page 23 CRUISER INSTALLATION FIGURE A.31 - BUTT JOINT, 3 WHEEL, GUIDE WHEEL, FRONT VIEW FIGURE A.32 - BUTT JOINT, 3 WHEEL, GUIDE WHEEL, REAR VIEW A 17...

  • Page 24: Fillet Joints

    CRUISER INSTALLATION FIGURE A.33 - BUTT JOINT, 3 WHEEL, GUIDE WHEEL, TOP VIEW FILLET JOINTS Horizontal Fillet Uses KP2721-2 curved nozzle extension (45°). FIGURE A.34 - HORIZONTAL FILLET, CURVED NOZZLE EXTENTION, FRONT VIEW A 18...
  • Page 25 CRUISER INSTALLATION FIGURE A.35 - HORIZONTAL FILLET, CURVED NOZZLE EXTENTION, REAR VIEW FIGURE A.36 - HORIZONTAL FILLET, CURVED NOZZLE EXTENTION, TOP VIEW A 19...

  • Page 26: Horizontal Fillet

    CRUISER INSTALLATION HORIZONTAL FILLET Uses KP2721-1 straight nozzle extensions. FIGURE A.37 - HORIZONTAL FILLET, STRAIGHT NOZZLE EXTENTION, FRONT VIEW FIGURE A.38 - HORIZONTAL FILLET, STRAIGHT NOZZLE EXTENTION, REAR VIEW A 20...
  • Page 27 CRUISER INSTALLATION FIGURE A.39 - HORIZONTAL FILLET, STRAIGHT NOZZLE EXTENTION, TOP VIEW FIGURE A.40 - HORIZONTAL FILLET TOP VIEW A 21...

  • Page 28: Flat Fillet

    CRUISER INSTALLATION FLAT FILLET (TROUGH) FIGURE A.41 - FLAT FILLET (TROUGH) FRONT VIEW FIGURE A.42 - FLAT FILLET (TROUGH) REAR VIEW A 22...
  • Page 29 CRUISER INSTALLATION FLAT FILLET (TROUGH) (CONTINUED) FIGURE A.43 - FLAT FILLET TOP VIEW FIGURE A.44 - FLAT FILLET TOP VIEW A 23...
  • Page 30 CRUISER INSTALLATION PIPE WELDING Internal inner diameter welds. The CRUISER™ may be assembled to fit inside pipes with a 44” (1.1m) inner diameter. FIGURE A.45 - PIPE WELDING FRONT VIEW FIGURE A.46 - PIPE WELDING REAR VIEW A 24...
  • Page 31 CRUISER INSTALLATION PIPE WELDING (CONTINUED) FIGURE A.47 - PIPE WELDING TOP VIEW FIGURE A.48 - PIPE WELDING TOP VIEW A 25...

  • Page 32: Base Dimensions Only

    CRUISER INSTALLATION BASE DIMENSIONS ONLY A 26...

  • Page 33: Operation

    • Always wear dry insulating gloves. responsibility of the builder / 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, welding procedure, plate chemistry and temperature, weldment design, fabrication methods and service requirements.

  • Page 34: Pendant Controls

    CRUISER OPERATION FIGURE B.1 - PENDANT CONTROLS MOVING THE TRACTOR 1. Engage the clutch at the rear of the tractor. The tractor will not travel unless the clutch is engaged. FIGURE B.3 - TRAVEL DIRECTION To engage the clutch, rotate the handle upwards. To disengage the clutch, rotate the handle to the 3 o’clock position.

  • Page 35: Power-Up Sequence

    CRUISER OPERATION When power is first applied to the CRUISER™ the LASER POINTER POWER-UP SEQUENCE CAUTION MODE SELECT Display reads “CRUISER™ Initializing...”. Once the Power Wave AC/DC has ini- tialized (20 to 60 seconds) a “lamp test” is performed. • Class II laser radiation present. Do not stare into laser beam or view directly with optical •...

  • Page 36: Wire Feeder Setup

    CRUISER OPERATION WIRE FEEDER SETUP CHANGING AND SETTING WELD MODES WARNING To select a weld mode, press the WELD MODE SELECTOR button until the WELD MODE indicator comes ON (it may already be lit by default at power ELECTRIC SHOCK can kill. up).

  • Page 37: Balance Adjust

    CRUISER OPERATION BALANCE ADJUST WELD SEQUENCE Press the WELD MODE selector until the MSP Display The weld sequence defines the weld procedure from reads “Balance”. If the selected mode allows for bal- beginning to end. All adjustments are made through ance adjustment, the Control Knob can be used to the user interface.

  • Page 38: Start Options Operation

    CRUISER OPERATION START OPTIONS OPERATION • RESTRIKE TIME determines how long the system will try to re-establish the arc in the event of a poor Pressing the Arc Start/End Options pushbutton will start or if the arc goes out for any reason (short cir- illuminate the START OPTIONS LED and the Arc cuit or open circuit).

  • Page 39: Memories

    CRUISER OPERATION MEMORIES The CRUISER™ has 4 memories. Each memory LIMITS stores : Limits allow the welder to adjust the welding procedure • Weld Mode only within a defined range. • Amperage (or WFS) • Voltage Each memory may have a different set of limits. For •...
  • Page 40 CRUISER OPERATION To set limits, press the desired memory button 1-8 and The Limits Setup menu shows a list of all parameters hold for 5 seconds. Release the memory button when available for the weld mode stored in the memory cho- the LED begins to blink rapidly and the MSP4 displays "Memory X Set Limits"...
  • Page 41 CRUISER OPERATION SETUP will light and the MSP4 displays the following: FIGURE B.23 - ENABLE/DISABLE LIMITS DISPLAY Press the left MSP4 button (YES) to enable limits or the right MSP4 button (NO) to disable limits. Disabling limits does not change any limits values that may have been previously set.

  • Page 42: Set-Up Features Menu

    CRUISER OPERATION SET-UP FEATURES MENU The Setup Menu gives access to the set-up configuration. Stored in the set-up configuration are user parameters that generally need to be set only at installation. The parameters are grouped as follows: PARAMETER DEFINITION P.1 through P.99 Unsecured Parameters (always adjustable) P.101 through P.199 Diagnostic Parameters (always read only)
  • Page 43 CRUISER OPERATION PARAMETER DEFINITION This parameter only appears with systems using Production Monitoring. P.14 Reset Consumable Weight Use this parameter to reset the initial weight of the consumable package. Enabled = touch sense is active when inching wire forward. P.15 Cold-Inch Touch Sense Option Disabled = touch sense is inactive when inching wire forward.
  • Page 44 CRUISER OPERATION PARAMETER DEFINITION Diagnostics are only used for servicing the Power Wave system. P.100 View Diagnostics Yes = Shows P.101 through P.500 in the SETUP menu. No = Only P.0 through P.100 are shown in the SETUP menu. Press the right MSP4 button to view the Event Logs. Rotate the encoder to P.101 Event Logs select the object to read and then press the right MSP4 button.
  • Page 45 CRUISER NOTES B 13...

  • Page 46: Accessories

    CRUISER ACCESSORIES OPTIONAL KITS AND ACCESSORIES DRIVE ROLL AND GUIDE TUBE KITS ITEM DESCRIPTION K1733-5 Wire Straightener KP1899-1 Drive Roll/ Guide Tube Kit, 3/32-7/32 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...

  • Page 47: Accessories Included With The Cruiser

    CRUISER ACCESSORIES K3090-1 Tube and clamp kit Includes: one 30” aluminum splined tube; one 15” aluminum splined tube; one 30” steel tube; 8 clamp assemblies with keys; 2 outrigger assemblies; hardware. K3089-1 Cross Slide Assembly Includes: two slides with 4 inches of travel.

  • Page 48: Maintenance

    CRUISER MAINTENANCE ROUTINE MAINTENANCE Blow out the slides PERIODIC MAINTENANCE Check wire drive motor brushes Lube gearbox for wire drive...
  • Page 49 CRUISER NOTES...

  • Page 50: Troubleshooting

    HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 51 CRUISER TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION A wire drive motor overload occurs. 1. Examine the contact tip for wear (Error 81) and proper size. Replace as necessary. 2. Verify the correct drive rolls and inner wire guide are installed in the wire drive.
  • Page 52 CRUISER TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED (SYMPTOMS) MISADJUSTMENTS(S) COURSE OF ACTION 1. Change P19 wire feed direction The wire drive feeds wire in the parameter in the Set-Up menu. wrong direction. The wire drive speed is incorrect.
  • Page 53 CRUISER DIAGRAMS...
  • Page 54 CRUISER NOTES...
  • Page 55 Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection. WARNING electrode with skin or wet clothing. Insulate yourself from work and ground. Spanish No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el AVISO DE bajo carga con la piel o ropa moja-...
  • Page 56 Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or WARNING Use ventilation or exhaust to guards off. remove fumes from breathing zone. Spanish Los humos fuera de la zona de res- Desconectar el cable de ali- No operar con panel abierto o AVISO DE...
  • Page 57 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.

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