SteelMax Rail Runner Manual de usuario

The tools of innovation.

15335 E. Fremont Drive, Centennial, CO 80112

1–87STEELMAX, FAX 303–690–9172

OPERATOR’S MANUAL

WELDING CARRIAGE

Contents 
 
 
GENERAL INFORMATION............................................................................................... 3 
1. Application................................................................................................................. 3 
2. Technical data............................................................................................................ 4 
3. Equipment included ................................................................................................... 5 
4. Dimensions................................................................................................................ 6 
5. Design ....................................................................................................................... 7 
SAFETY PRECAUTIONS.................................................................................................. 8 
STARTUP AND OPERATION..........................................................................................10 
1. Assembling the track.................................................................................................10 
2. Assembling the holder...............................................................................................12 
3. Positioning................................................................................................................13 
4. Connecting to the welding circuits.............................................................................14 
5. Operating..................................................................................................................15 
6. Changing the unit of measure...................................................................................17 
7. Troubleshooting........................................................................................................18 
MAINTENANCE...............................................................................................................19 
ACCESSORIES...............................................................................................................20 
1. Semi-flexible track.....................................................................................................20 
2. Rigid track.................................................................................................................20 
3. Rack adjustment tool.................................................................................................20 
4. Magnetic units...........................................................................................................21 
5. Semi-flexible track support.......................................... Error! Bookmark not defined. 
6. Transport attachment................................................................................................25 
7. 76 mm cross slide.....................................................................................................26 
8. Vacuum track system................................................................................................27 
9. Torch clamps............................................................................................................28 
10. Rods .......................................................................................................................29 
11. Torch holders..........................................................................................................30 
115–230 V WIRING DIAGRAM........................................................................................32 
42 V WIRING DIAGRAM..................................................................................................33 
115–230 V EXPLODED VIEWS AND PARTS LIST..........................................................34 
42 V EXPLODED VIEWS AND PARTS LIST ...................................................................39 
DECLARATION OF CONFORMITY ...............................................................................44 
QUALITY CERTIFICATE................................................................................................45 
WARRANTY CARD........................................................................................................46 

Rail Runner

Rail Runner Operator’s Manual

1. GENERAL INFORMATION

1.1. Application

The Rail Runner is a track carriage designed to make butt and fillet welds with or

without oscillation. The carriage allows MIG/MAG torches with the handle diameter of

16–22 mm (0.63–0.87″). It can work in the following welding positions: PA/1F/1G,

PB/2F, PC/2G, PD/4F, PE/4G, PF/3G, and PG/3F/3G. The track is fixed by using

magnetic units to ferromagnetic surfaces that are flat or curved with a radius of at

least 5 m (16 ft).

Accessories allow, for instance, using torches with the handle diameter larger than

22 mm (0.87″)and guiding the carriage on asemi-flexible or rigid track. Using a vacuum

track system allows the track to be fixed to surfaces that are non-ferromagnetic.

Rail Runner

Rail Runner Operator’s Manual

1.2. Technical data

Voltage

1~ 115–230 V, 50–60 Hz

1~ 42 V, 50–60 Hz (60 V DC)

Power

100 W

Welding position

(according to EN ISO 6947

and AWS/ASME)

Horizontal

PA / 1F / 1G

PB / 2F

PC / 2G

PD / 4F

PE / 4G

Vertical

PF / 3G

PG / 3F (contact your dealer)

PG / 3G

Minimum curve radius of a semi-flexible track

5 m (16 ft)

Torch type

MIG/MAG

Torch diameter

16–22 mm (0.63–0.87″)

Minimum workpiece thickness for magnetic

clamping

5 mm (0.2″)

Horizontal pulling force

350 N (77 lbs)

Vertical pulling force

150 N (33 lbs)

Cross slide adjustment range

0–35 mm (0–1.38″, up-down, left-right)

Horizontal speed

0–120 cm/min (0–47.2 in/min)

Vertical speed

0–110 cm/min (0–43.3 in/min)

Oscillation type

Linear

Oscillation path

Trapezoid, triangle, straight line

Oscillator arm stroke

0–100 mm (0–3.9″)

Oscillation width

0–50 mm (0–1.9″)

Oscillation speed

0–1500 mm/min (0–59 in/min)

Oscillation dwell time at center and on ends

0–5 s

Maximum oscillator pulling force

100 N (22 lbs)

Maximum allowed ambient temperature

50°C (122°F)

Maximum allowed ambient humidity

85%

Weight

20 kg (44 lbs)

Rail Runner

Rail Runner Operator’s Manual

1.3. Equipment included

Carriage

1 unit

Metal box

1 unit

Cross slide assembly

1 unit

Long rod torch holder with clip

1 unit

3 m (10 ft) power cord

1 unit

6.5 m (21 ft) arc ignition cable

1 unit

3 mm hex wrench

1 unit

4 mm hex wrench

1 unit

–

Operator’s Manual

1 unit

Rail Runner

Rail Runner Operator’s Manual

1.4. Dimensions

362 mm (14.3’’)

644 mm (25.4’’)

441 mm (17.4’’)

Rail Runner

Rail Runner Operator’s Manual

1.5. Design

Oscillation width knob

Oscillation speed knob

Arc ignition switch

(TEST / O / I)

Travel direction switch

(Forward / O / Backward)

Oscillation offset knob (arm stroke)

Travel

speed

knob

Left oscillation position dwell knob

Right oscillation position dwell knob

Center oscillation position dwell knob

Pressing lever

Control

panel

Oscillator arm

Cable anchor

Cross slide

Power switch

Arc ignition socket

Drive clutch knob

Display

Carrying handle

Clamping block

Long rod

Rail Runner

Rail Runner Operator’s Manual

2. SAFETY PRECAUTIONS

1. Before starting, read this Operator’s Manual and complete proper occupational

safety and health training.

2. Use the carriage only in applications specified in this Operator’s Manual.

3. The carriage must be complete and all parts must be genuine and fully functional.

4. The specifications of the power source must conform to those specified on the

rating plate.

5. Connect the carriage into a properly grounded power source.

6. Never carry the carriage by the cords or arc ignition cable. Never pull them because

this may damage them and result in electric shock.

7. Untrained bystanders must not be present near the carriage.

8. Before starting, ensure the correct condition of the carriage, power source, cords,

arcignition cable, plugs, controlpanel, rollers, and gear.

9. Keep the carriage dry, and never expose it to rain, snow, or frost.

10. Keep the work area well lit, clean, and free of obstacles.

11. Never use near flammable liquids or gases, or in explosive environments.

12. Transport and position the carriage by using the carrying handles.

13. Install the carriage only on the supplied track.

14. Make sure that the gear and rollers are clean and not damaged.

15. Plug the cords and arc ignition cable into sockets only when the power switch is

set to ‘O’.

16. Keep the sockets clean. Do not use compressed air for cleaning.

17. Install only MIG/MAG torches whose handle diameter is the same as the diameter

of the torch holder in use.

18. Suspend cables to reduce the load of the carriage.

19. Do not bend the semi-flexible track to a radius less than 5 m (16 ft).

20. Use the rigid track only on flat surfaces.

21. At heights, protect the carriage and the track from falling. To do this, fasten the

track to a fixed structure with chains attached to the leftmost and rightmost

magnetic units. Protect the carriage by attaching a chain to a carrying handle.

The chains must not be loose.

22. Do not stay below the carriage or the track placed at heights.

Rail Runner

Rail Runner Operator’s Manual

23. Always use eye protection (helmet, shield, and screen), hearing protection, gloves,

and protective clothing during work. Do not wear loose clothing.

24. Before every use, inspect the carriage to ensure it is not damaged. Check whether

any part is cracked or improperly fitted. Make sure to maintain proper conditions

that may affect the operation of the carriage.

25. Never try to manually stop the travel. To stop, set the travel direction switch to ‘O’.

26. Maintain only when the carriage is unplugged from the power source.

27. Repair only in a service center appointed by the seller.

28. If the carriage falls from any height, is wet, or has any other damage that could

affect the technical state of the carriage, stop the work and promptly send the

carriage to the service center for inspection and repair.

29. Never leave the carriage unattended during work.

30. Remove from the worksite and store in a secure and dry place when not in use.

Rail Runner

Rail Runner Operator’s Manual

3. STARTUP AND OPERATION

3.1. Assembling the track

Connect magnetic units to the rail, and position it on the workpiece. Use the 4 mm

hex wrench to attach additional rails (1, Fig. 1), and then switch the levers of the

magnetic units to ‘I’ (2). This will clamp the track to the surface.

When working in PC/2G welding position, place the track so that the teeth of the

racks are directed downward.

Fig. 1. Connecting the rails and clamping the magnetic units to the surface

Before attaching additional rails to a semi-flexible rail placed on a curve, use the

4 mm hex wrench to loosen the screws of the connecting plates (1, Fig. 2) and of

the racks (2). Next, attach the rails, clamp them with levers, and then tighten the

connecting plates. Place the rack adjustment tool (not included) into the hole (3), and

rotate the tool to the left (4) to remove the gap (5) between the racks. Then, tighten

the leftmost screw and the rightmost screw of each rack (2).

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