SteelMax Rail Runner LT User manual

The tools of innovation.
112 Inverness Circle East Suite F Englewood, CO 80112
1–87STEELMAX, FAX [phone]
www.steelmax.com [e-mail]
OPERATOR’S MANUAL
R
Ra ai il l R Ru un nn ne er r L LT T
WELDING CARRIAGE

Contents
1. GENERAL INFORMATION ................................................................................................3
1.1. Application..................................................................................................................3
1.2. Technical data.............................................................................................................3
1.3. Equipment included ....................................................................................................4
1.4. Dimensions.................................................................................................................5
1.5. Design ........................................................................................................................6
2. SAFETY PRECAUTIONS...................................................................................................7
3. STARTUP AND OPERATION............................................................................................9
3.1. Assembling the semi-flexible or rigid track ..................................................................9
3.2. Assembling the ring track..........................................................................................11
3.3. Positioning on a straight track...................................................................................13
3.4. Positioning on a curved track....................................................................................15
3.5. Preparing..................................................................................................................16
3.6. Connecting to the welding or plasma cutting circuits.................................................18
3.7. Operating..................................................................................................................19
3.8. Adjusting the pressure of rollers................................................................................20
3.9. Troubleshooting........................................................................................................21
4. MAINTENANCE...............................................................................................................22
5. ACCESSORIES ...............................................................................................................23
5.1. MIG/MAG welding set...............................................................................................23
5.2. SAW welding set.......................................................................................................23
5.3. Oxy-fuel cutting set ...................................................................................................24
5.4. Plasma cutting set.....................................................................................................24
5.5. Semi-flexible track.....................................................................................................25
5.6. Rigid track.................................................................................................................25
5.7. Rack adjustment tool.................................................................................................25
5.8. Magnetic units...........................................................................................................26
5.9. Semi-flexible track support........................................................................................30
5.10. Vacuum track system..............................................................................................31
5.11. Ring tracks..............................................................................................................32
5.12. Ring track supports .................................................................................................34
5.13. Rack........................................................................................................................35
5.14. Torch clamps...........................................................................................................36
5.15. Rods .......................................................................................................................37
5.16. Torch holders..........................................................................................................38
5.17. Pivoting support ......................................................................................................40
5.18. Cutting torch holders...............................................................................................41
5.19. Gas manifold (for oxy-fuel cutting)...........................................................................43
6. WIRING DIAGRAM..........................................................................................................45
7. EXPLODED VIEWS AND PARTS LIST............................................................................46
8. DECLARATION OF CONFORMITY.................................................................................51
9. QUALITY CERTIFICATE..................................................................................................52
10. WARRANTY CARD.......................................................................................................53

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1. GENERAL INFORMATION
1.1. Application
The Rail Runner LT is a track carriage designed to cut and to make butt and fillet
welds. The carriage allows MIG/MAG, SAW, oxy-fuel, or plasma torches. The track is
clamped with magnetic units to ferromagnetic surfaces that are flat or curved.
Accessories allow, for example, using torches with a larger diameter, and guiding
the carriage on a semi-flexible, rigid, or ring 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
Power
66 W
Welding position
(according to EN ISO 6947 and
AWS/ASME)
Horizontal
PA / 1F / 1G
PB / 2F
PC / 2G
PD / 4F
PE / 4G
Vertical
PG / 3G
Minimum curve radius of a semi-flexible track
5 m (16 ft)
Torch type
MIG/MAG, SAW, oxy-fuel, plasma
Torch diameter
MIG/MAG
16–22 mm (0.63–0.87″)
SAW, plasma
28–35 mm (1.10–1.38″)
Oxy-fuel
35 mm (1.38″)
Minimum workpiece thickness for magnetic clamping
5 mm (0.2″)
Horizontal pulling force
300 N
Vertical pulling force
200 N
Horizontal speed
10–200 cm/min (4–80 in/min)
Vertical speed
10–200 cm/min (4–80 in/min)
Allowed ambient temperature
0–50°C (32–122°F)
Maximum allowed ambient humidity without
condensation
80%
Protection level
IP 23
Weight
10 kg (22 lbs)

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1.3. Equipment included
1
Carriage
1 unit
2
Cardboard box
1 unit
3
6 mm hex wrench
1 unit
4
3 m (10 ft) power cord
1 unit
–
Operator’s Manual
1 unit
4
1
3
2

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1.4. Dimensions
379 mm (14.9″)
713 mm (28.1″)
334 mm (13.1″)

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1.5. Design
Levers to hold the rack in position
Rack adjustment knob
540 mm (21″) rack
Control panel
Carrying handle
Travel speed knob
Display
Power switch
Travel direction switch (Forward / O / Backward)
Arc ignition switch (I / O / TEST)
Passive roller
Drive clutch knob
Pressing
roller
Pressing lever (pressing
rollers are loose in this position)
Drive gear
Install bracket
Arc ignition
socket
Set for MIG/MAG welding

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2. SAFETY PRECAUTIONS
1. Before starting, read this Operator’s Manual and complete occupational safety and
health training.
2. Use only in applications specified in this Operator’s Manual.
3. Make sure that the carriage is complete and all parts 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 cables, and do not pull them. This can
cause damage and electric shock.
7. Keep untrained bystanders away from the carriage.
8. Before starting, ensure the correct condition of the carriage, power source, cords,
arc ignition cable, connections, rollers, and gear.
9. Keep the carriage dry. Do not expose it to rain, snow, or frost.
10. Keep the work area well lit, clean, and free of obstacles.
11. Do not use near flammable materials, 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.
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 high pressure during cleaning.
17. Install only torches whose diameter matches the diameter of the torch holder.
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, use chains
(not included) to attach the leftmost and rightmost magnetic units of the semi-
flexible or rigid track to a stable structure. To protect the carriage, attach a chain to
a carrying handle. The chains must not be loose.
22. Do not stay below the carriage or the track that is put at heights.
23. Use eye protection (helmet, shield, and screen), hearing protection, gloves, and
protective clothing during work. Do not use loose clothing.

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24. Before every use, make sure that the carriage is not damaged and no part is
cracked or loose. Make sure to maintain correct conditions that can affect the
operation of the carriage.
25. Do not try to stop the travel by hand. To stop, set the travel direction switch to ‘O’.
26. Maintain 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 from any height, 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. When the carriage is not in use, remove it from the worksite and keep in a safe
and dry place.

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3. STARTUP AND OPERATION
3.1. Assembling the semi-flexible or rigid track
Connect 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-flexible 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).
1
2

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Fig. 2. Removing the gap between the racks of a semi-flexible track
1
2
5
3
4

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3.2. Assembling the ring track
Select the track that matches the outer diameter of the round workpiece. Use the
4 mm hex wrench to attach the supports to the rails (1, Fig. 3). Next, on all supports,
retract the bolts (2, or screws) as much as possible.
Fig. 3. Connecting the supports to the rails
Put the workpiece vertically, and then put the rails onto the workpiece so that the
teeth of the racks point down. Next, for all rails, use the 12 mm hex wrench to set
the hinge as shown in Fig. 4. Then, put the lock pin through the holes (1), and then
rotate the wrench (2) to connect the rails.
1
2
2
Screw with plastic foot
25 mm (1″) adjustment range
Bolt
25 mm (1″) adjustment range
Screw with magnet
25 mm (1″) adjustment range

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Fig. 4. Connecting the rails of the ring track
Use the 13 mm flat wrench to adjust the bolts (or the screws by hand) until they contact
the workpiece (1, Fig. 5). Adjust each support equally to make the track concentric
to the workpiece. Lock the supports with the nuts (2) or levers.
Fig. 5. Attaching the ring track to the workpiece
1
2
2
1

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3.3. Positioning on a straight track
Set the power switch, arc ignition switch, and travel direction switch to ‘O’. Next, set
the levers to OFF (1, Fig. 6), and then loosen the knob (2)fully to retract the gear (3).
Then, put the carriage so that the install brackets are on the rail (4, 5).
Fig. 6. Putting the carriage on a straight track
2
3
5
Gear
retracted
4
1
Install bracket

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Set the levers to ON (1, Fig. 7) to put the rollers into the grooves (2). Then, while
moving the carriage slightly left or right, tighten the knob (3)to engage the gear of the
carriage with the rack of the rail (4). However, do not tighten the knob with too much
force. Keep some backlash between the gear and rack.
Fig. 7. Engaging the carriage with the track
3
Not engaged
×
Engaged
✓
1
1
2
2
4

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3.4. Positioning on a curved track
Use the 6mm hex wrench to loosen four screws (1, Fig.8),and then put the carriage on
the track. Rotate two roller brackets (2) to put the rollers into the grooves, and then set
the levers to ON (3). Next, move the carriage left or right and make sure that it moves
smoothly. Then, tighten the screws (1) and the knob (4).
Fig. 8. Rotating the rollers for a curved track
1
2
2
3
4

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3.5. Preparing
Install an optional welding/cutting set as shown in Fig. 9.
MIG/MAG welding
SAW welding

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Fig. 9. Installing the welding/cutting set
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 semi-flexible
or rigid track to a stable structure. To protect the carriage, attach a chain to a carrying
handle. The chains must not be loose.
Connect the carriage to the power source. Then, put the torch and torch cables
into the holders.
Oxy-fuel cutting
Plasma cutting

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3.6. Connecting to the welding or plasma cutting circuits
The carriage can control two torches by using the arc ignition cable plugged into the
arc ignition socket. To do this, according to the diagram shown in Fig. 10 connect
one blue-jacketed wire to one terminal of the welding / plasma cutting circuit. Then,
connect the other blue-jacketed wire to the other terminal of the same circuit.
To control the second torch, connect the green-jacketed wires to the terminals of the
second welding circuit.
Fig. 10. Connecting the arc ignition cable to welding / plasma cutting circuits
Make sure that the arc ignition cable is connected correctly. To do this, turn on the
power of the carriage, and then set the arc ignition switch to TEST. This should
enable the arc for a while.
Blue Blue
Green Green
Circuit 2
Circuit 1

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3.7. Operating
Set the travel direction switch and arc ignition switch to ‘O’. Next, set the power switch
to ‘I’ to turn on the power. The whole display will then lit ( ). Then, shows (for
centimeters per minute) or (for inches per minute). Next, the carriage speed
shows. Use the knob to set the required speed.
To control the torch through the carriage, set the arc ignition switch to ‘I’.
Use the travel direction switch to select a direction of travel. Then, the travel
starts with the speed that is shown. You can adjust the speed at any time.
To stop the travel, set the travel direction switch to ‘O’.
After the work is finished, use the power switch to turn off the power. Then,
unplug the carriage from the power source.
If the arc ignition switch is set to ‘I’, the torch starts welding /
plasma cutting promptly after selecting a travel direction.