SteelMax Rail Runner Manuel utilisateur

The tools of innovation.

15335 E. Freemont 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............................................................................................................ 3 
3. Equipment included ................................................................................................... 4 
4. Dimensions................................................................................................................ 5 
5. Design ....................................................................................................................... 6 
SAFETY PRECAUTIONS.................................................................................................. 7 
STARTUP AND OPERATION........................................................................................... 9 
1. Assembling the track.................................................................................................. 9 
2. Assembling the holder...............................................................................................11 
3. Positioning................................................................................................................12 
4. Connecting to the welding circuits.............................................................................13 
5. Operating..................................................................................................................14 
6. Changing the unit of measure...................................................................................16 
7. Troubleshooting........................................................................................................17 
MAINTENANCE...............................................................................................................18 
ACCESSORIES...............................................................................................................19 
1. Semi-flex track..........................................................................................................19 
2. Rigid track.................................................................................................................19 
3. Rack adjustment tool.................................................................................................19 
4. Magnetic units...........................................................................................................20 
5. Semi-flex track support .............................................................................................24 
6. Transport attachment................................................................................................24 
7. 76 mm cross slide.....................................................................................................25 
8. Vacuum track system................................................................................................26 
9. Torch holders, clamps, and rods...............................................................................27 
115–230 V WIRING DIAGRAM........................................................................................29 
42 V WIRING DIAGRAM..................................................................................................30 
115–230 V EXPLODED VIEWS AND PARTS LIST..........................................................31 
42 V EXPLODED VIEWS AND PARTS LIST ...................................................................36 
DECLARATION OF CONFORMITY...............................................................................41 
WARRANTY CARD........................................................................................................42 

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 by using MIG/MAG torches. The track is fixed by using magnetic

units to ferromagnetic surfaces that are flat or curved.

Accessories allow using torches with a larger diameter and guiding the carriage

on a semi-flex or rigid track. Using a vacuum track system allows the track to be

clamped to surfaces that are non-ferromagnetic.

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-flex 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 use, read this Operator’s Manual and complete a training in occupational

safety and health.

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

3. Make sure that the carriage has all parts and they are genuine and not damaged.

4. Make sure that the specifications of the power source are the same as those

specified on the rating plate.

5. Connect the carriage to a correctly grounded power source.

6. Do not carry the carriage by the cords or arc ignition cable, and do not pull them.

This can cause damage and electric shock.

7. Keep untrained bystanders away from the carriage.

8. Before each use, ensure the correct condition of the carriage, power source,

cords, arc ignition cable, plugs, control panel, rollers, and gear.

9. Before each use, make sure that no part is cracked or loose. Make sure to

maintain correct conditions that can have an effect on the operation of the

carriage.

10. Keep the carriage dry. Do not expose the carriage to rain, snow, or frost.

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

12. Do not use near flammable materials, or in explosive environments.

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

14. Install the carriage only on the supplied track.

15. Make sure that the gear and rollers are clean.

16. Connect the cords and the arc ignition cable only after you set the power switch

to ‘O’.

17. Keep the sockets clean. Do not use high pressure during cleaning.

18. Install only torches whose diameter matches the diameter of the torch holder.

19. Hang the cables to decrease the load applied on the carriage.

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

21. Use the rigid track only on flat surfaces.

22. At heights, protect the carriage and the track from falling. To do this, use chains

(not included) to attach the leftmost and rightmost magnetic units of the track to a

stable structure. To protect the carriage, attach a chain to a carrying handle.

Make sure that the chains are not loose.

Rail Runner

Rail Runner Operator’s Manual

23. Do not stay below the carriage or the track that is put at heights.

24. Use eye protection (helmet, shield, and screen), ear protection, gloves, and

protective clothing. Do not use loose clothing.

25. Do not stop the carriage by hand. To stop, set the travel direction switch to ‘O’.

26. Do the maintenance only after you unplug the carriage from the power source.

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

28. If the carriage falls, is wet, or has any damage, stop the work and promptly send

the carriage to the service center for check and repair.

29. Do not leave the carriage unattended during work.

30. If you are not going to use the carriage, remove it from the work area and keep in

a safe and dry place.

Rail Runner

Rail Runner Operator’s Manual

3. STARTUP AND OPERATION

3.1. Assembling the track

Attach magnetic units to the rail, and put it on the workpiece. Use the 4 mm hex

wrench to attach more rails (1, Fig. 1). Then, set the levers of the magnetic units to ‘I’

(2). This will clamp the track to the surface.

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

racks point down.

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

If a semi-flex rail is put on a curve, before you attach more rails 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.

Put 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).

Rail Runner

Rail Runner Operator’s Manual

Fig. 2. Removing the gap between the racks of a semi-flex track

Autres manuels pour Rail Runner

Table des matières

Autres manuels SteelMax Système de soudage

SteelMax

SteelMax Li'l Runner Manuel utilisateur

SteelMax

SteelMax Rail Runner 2 Manuel utilisateur

SteelMax

SteelMax Rail Runner Gen III Manuel utilisateur

SteelMax

SteelMax Rail Runner LT Manuel utilisateur

SteelMax

SteelMax ARC Runner Manuel utilisateur

Manuels Système de soudage populaires d'autres marques

Berner

Berner PLASMACUT 54 Manuel utilisateur

Pro Spot

Pro Spot PR-155 Manuel utilisateur

Forney

Forney 210 Manuel utilisateur

Thermal Arc

Thermal Arc 400S Manuel utilisateur

Lincoln Electric

Lincoln Electric HANDYMIG 170I Manuel utilisateur

GYS

GYS PROTIG 201 AC/DC Manuel utilisateur

TAFA

TAFA 30*8B35 Manuel utilisateur

Lincoln Electric

Lincoln Electric INVERTEC V350-PRO CE Manuel utilisateur

ESAB

ESAB Buddy Arc 145 Manuel utilisateur

CIGWELD

CIGWELD 636804 Guide rapide

Red-D-Arc

Red-D-Arc DC-400 Manuel utilisateur

Hobart Welding Products

Hobart Welding Products Spool Gun DP 3035-10 Manuel utilisateur

Elettro

Elettro HI-MIG 3000 SYNERGIC Manuel utilisateur

WIA

WIA Weldmatic 270 CP132-2 Manuel utilisateur

Sonics

Sonics H520T Manuel utilisateur

Miller

Miller Big Blue 400D Manuel utilisateur

NewArc

NewArc RT2000 Guide de démarrage rapide

Hypertherm

Hypertherm powermax1000 Manuel utilisateur