SteelMax Rail Runner LT User manual

The tools of innovation.
15335 E. Freemont Drive, Centennial, CO 80112
1–87STEELMAX, FAX [phone]
www.steelmax.com [email protected]
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 hi-flex, semi-flex, 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. Hi-flex track...............................................................................................................25
5.6. Semi-flex track..........................................................................................................26
5.7. Rigid track.................................................................................................................26
5.8. Rack adjustment tool.................................................................................................26
5.9. Magnetic units...........................................................................................................27
5.10. Semi-flex track support............................................................................................32
5.11. Vacuum track system..............................................................................................33
5.12. Ring tracks..............................................................................................................34
5.13. Ring track supports and bracket..............................................................................36
5.14. Rack........................................................................................................................37
5.15. Torch holders, clamps, and rods.............................................................................38
5.16. Cutting torch holders...............................................................................................40
5.17. Gas manifold (for oxy-fuel cutting)...........................................................................42
6. WIRING DIAGRAM..........................................................................................................44
7. EXPLODED VIEWS AND PARTS LIST............................................................................45
8. DECLARATION OF CONFORMITY.................................................................................49
9. WARRANTY CARD..........................................................................................................50

Rail Runner LT
Rail Runner LT –Operator’s Manual
3
1. GENERAL INFORMATION
1.1. Application
The Rail Runner LT is a track carriage designed to cut and to make butt and fillet
welds. 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 using torches with a larger diameter, and guiding the carriage
on a hi-flex, semi-flex, 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/3F (contact your dealer)
Diameter
of round workpiece
Ring tracks (OD)
200 mm (8″) – 3 m (10 ft)
Hi-flex tracks (OD)
Minimum 1.5 m (5 ft)
Hi-flex tracks (ID)
Minimum 3.4 m (11 ft)
Custom rolled tracks (OD)
3–10 m (10–32 ft)
(contact your dealer)
Semi-flex tracks (OD)
Minimum 10 m (32 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 non-condensing
80%
Protection level
IP 23
Weight
10 kg (22 lbs)

Rail Runner LT
Rail Runner LT –Operator’s Manual
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1.3. Equipment included
1
Carriage with a 540 mm (21″) rack
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

Rail Runner LT
Rail Runner LT –Operator’s Manual
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1.4. Dimensions
379 mm (14.9″)
713 mm (28.1″)
334 mm (13.1″)