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Rail Runner LT

Rail Runner LT

– Operator’s Manual

24

5.3. Oxy-fuel cutting set

1

Precise machine torch holder 35 mm (

1.38″)

1 unit

2

2/2 gas manifold with cut-off valve (imperial)

1 unit

3

4 mm hex wrench

1 unit

5.4. Plasma cutting set

1

Precise torch holder 28

–35 mm (1.10–1.38″)

1 unit

2

Cable anchor

1 unit

3

6.5 m (21 ft) arc ignition cable

1 unit

Part number:
ZST-0570-03-01-00-0

1

2

3

Part number:
ZST-0570-03-02-00-0

1

2

3

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Summary of Contents for Rail Runner LT

Page 1: ...ls of innovation 112 Inverness Circle East Suite F Englewood CO 80112 1 87STEELMAX FAX 303 690 9172 www steelmax com sales steelmax com OPERATOR S MANUAL R Ra ai il l R Ru un nn ne er r L LT T WELDING CARRIAGE ...

Page 2: ... 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 clam...

Page 3: ...hat 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 workpi...

Page 4: ...Rail Runner LT Rail Runner LT Operator s Manual 4 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 ...

Page 5: ...Rail Runner LT Rail Runner LT Operator s Manual 5 1 4 Dimensions 379 mm 14 9 713 mm 28 1 334 mm 13 1 ...

Page 6: ...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 ...

Page 7: ...mmable 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 w...

Page 8: ...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 ...

Page 9: ...rack 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 too...

Page 10: ...Rail Runner LT Rail Runner LT Operator s Manual 10 Fig 2 Removing the gap between the racks of a semi flexible track 1 2 5 3 4 ...

Page 11: ...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 rang...

Page 12: ...g 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 ...

Page 13: ...tch 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 ...

Page 14: ...ves 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 ...

Page 15: ...r 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 ...

Page 16: ...Rail Runner LT Rail Runner LT Operator s Manual 16 3 5 Preparing Install an optional welding cutting set as shown in Fig 9 MIG MAG welding SAW welding ...

Page 17: ...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 ...

Page 18: ...ing 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...

Page 19: ...red 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 po...

Page 20: ...nd 8 mm flat wrenches to loosen the bolts 2 and nuts 3 Next use the 2 5 mm hex wrench to adjust the screws 4 and then tighten the bolts 2 Travel the carriage along the track If the resistance is still incorrect repeat the above steps If the carriage travels smoothly use the 2 5 mm hex wrench to prevent rotation of each screw 4 Then use the 8 mm flat wrench to tighten the nuts 3 Fig 11 Adjusting th...

Page 21: ...g travel indicates a malfunction of the switch or controller 1 Set the travel direction switch to O If the message still shows contact service center for check and repair 2 Contact service center for check and repair Arc ignition switch not set to O when powering Set the arc ignition switch to O If the message still shows contact service center for check and repair Motor overload that promptly sto...

Page 22: ...e and the rack of each rail 2 Clean the rollers and make sure that they rotate freely 3 Clean the torch nozzle Replace if damaged Monthly 1 Make sure that the knobs and the switches work as intended Replace if loose or damaged 2 Examine cables cords and hoses Replace if damaged 3 Tighten screws if loose ...

Page 23: ...m 0 63 0 87 1 unit 5 Cable anchor 1 unit 6 6 5 m 21 ft arc ignition cable 1 unit 5 2 SAW welding set 1 300 mm 12 rack with 180 mm 7 adjustment 1 unit 2 Rack holder 1 unit 3 Clamping block with levers 1 unit 4 Cutting torch clamp 28 35 mm 1 10 1 38 1 unit 5 Short rod 1 unit 6 Cable anchor 1 unit 7 6 5 m 21 ft arc ignition cable 1 unit 1 2 3 4 5 5 5 6 5 7 5 Part number ZST 0570 03 04 00 0 1 2 3 4 5 ...

Page 24: ... 35 mm 1 38 1 unit 2 2 2 gas manifold with cut off valve imperial 1 unit 3 4 mm hex wrench 1 unit 5 4 Plasma cutting set 1 Precise torch holder 28 35 mm 1 10 1 38 1 unit 2 Cable anchor 1 unit 3 6 5 m 21 ft arc ignition cable 1 unit Part number ZST 0570 03 01 00 0 1 2 3 Part number ZST 0570 03 02 00 0 1 2 3 ...

Page 25: ...e rail is 2 m 6 5 ft 5 6 Rigid track Allows guiding the carriage along a straight line The length of a single rail is 2 m 6 5 ft 5 7 Rack adjustment tool Removes the clearance between the racks of two semi flexible rails that are put on a curve Part number PRW 0482 15 05 00 0 Part number PKT 0341 13 00 00 0 Part number PRW 0482 47 00 00 0 ...

Page 26: ...e 4 mm hex wrench M6x20 screws and 6 4 mm washers to tighten the bracket to the unit Then use the 4 mm hex wrench and M6x16 screws to tighten the bracket to the rail Attach the unit to a rigid rail as shown in the right figure Use the 4 mm hex wrench M6x16 screws and 6 4 mm washers to tighten the bracket to the unit Then use the 4 mm hex wrench and M6x35 screws to tighten the bracket to the rail M...

Page 27: ...iffer in height up to 80 mm 3 1 The holding force on a 5 mm 0 2 thick surface is 1200 N up to a temperature of 100 C 212 F At 180 C 356 F the force decreases to 720 N Install the unit in the same way as the magnetic unit is installed To adjust the angle use the 6 mm hex wrench and loosen four side screws Part number ZSP 0475 85 00 00 0 Part number bracket for semi flexible track DYS 0482 19 00 00 ...

Page 28: ...0 230 mm 6 7 9 1 The holding force on a 5 mm 0 2 thick surface is 1200 N up to a temperature of 100 C 212 F At 180 C 356 F the force decreases to 720 N Install the unit in the same way as the magnetic unit is installed To adjust the spacing use the 5 mm hex wrench and loosen four side screws Part number ZSP 0523 19 00 00 0 Part number bracket for semi flexible track DYS 0482 19 00 00 0 Part number...

Page 29: ...exible rail as shown in the left figure Use the 4 mm hex wrench and M6x16 cylinder head screws to tighten the bracket to the unit Then use the 4 mm hex wrench and M6x16 button head screws to tighten the bracket to the rail Attach the unit to a rigid rail as shown in the right figure Use the 4 mm hex wrench and M6x35 screws To clamp the unit to the surface use the 17 mm flat wrench not included and...

Page 30: ...ual 30 5 9 Semi flexible track support Allows supporting a semi flexible track by using the support instead of a magnetic unit To attach the support to a semi flexible rail use the 4 mm hex wrench and M6x16 screws Part number WSP 0523 12 01 00 1 ...

Page 31: ... 5 10 Vacuum track system Dedicated to clamping the track to non ferromagnetic surfaces Part number vacuum pump with safety reservoir AGR 0541 10 10 00 0 115 V UK AGR 0541 10 20 00 0 230 V CEE Other parts of the system are described in a related manual ...

Page 32: ...TRO 0523 20 00 00 0 350 400 TRO 0523 21 00 00 0 400 450 TRO 0523 23 00 00 0 450 500 TRO 0523 24 00 00 0 500 550 TRO 0523 25 00 00 0 550 600 TRO 0523 26 00 00 0 600 650 TRO 0523 22 00 00 0 650 700 TRO 0523 28 00 00 0 700 750 TRO 0523 29 00 00 0 750 800 TRO 0523 30 00 00 0 800 850 TRO 0523 31 00 00 0 850 900 TRO 0523 32 00 00 0 900 950 TRO 0523 33 00 00 0 950 1000 TRO 0523 34 00 00 0 1000 1050 TRO 0...

Page 33: ...1950 2000 TRO 0523 54 00 00 0 2000 2050 TRO 0523 55 00 00 0 2050 2100 TRO 0523 56 00 00 0 2100 2150 TRO 0523 57 00 00 0 2150 2200 TRO 0523 58 00 00 0 2200 2250 TRO 0523 59 00 00 0 2250 2300 TRO 0523 60 00 00 0 2300 2350 TRO 0523 61 00 00 0 2350 2400 TRO 0523 62 00 00 0 2400 2450 TRO 0523 63 00 00 0 2450 2500 TRO 0523 64 00 00 0 2500 2550 TRO 0523 65 00 00 0 2550 2600 TRO 0523 66 00 00 0 2600 2650 ...

Page 34: ...al 34 5 12 Ring track supports 5 12 1 Ring track support with bolts 5 12 2 Ring track support with plastic feet 5 12 3 Ring track support with magnets Part number WSP 0523 14 02 00 0 Part number WSP 0523 14 11 00 0 Part number WSP 0523 14 12 00 0 ...

Page 35: ...e horizontal or vertical reach of the torch holder Loosen the levers 1 and remove the installed rack Point the teeth of the rack to the side 2 and move the rack into the carriage 3 1 3 2 Part number total length RAM 0475 07 03 00 0 700 mm 28 RAM 0475 23 00 00 0 1000 mm 39 ...

Page 36: ... 0 63 0 87 5 14 2 16 22 mm torch clip The clip allows using a torch with the diameter of 16 22 mm 0 63 0 87 Use the 4 mm hex wrench to tighten the torch in the clip 5 14 3 22 35 mm torch clamp Allows using a torch with the diameter of 22 35 mm 0 87 1 38 Part number ZRZ 0466 19 00 00 0 Part number ZRZ 0466 04 01 00 0 Part number ZCS 0476 06 01 00 0 ...

Page 37: ...unner LT Rail Runner LT Operator s Manual 37 5 15 Rods 5 15 1 Short rod Provides a 120 mm 4 7 reach 5 15 2 Long rod Provides a 240 mm 9 4 reach Part number WLK 0476 20 01 00 0 Part number WLK 0466 04 10 00 0 ...

Page 38: ...th clip The holder allows using a torch with the diameter of 16 22 mm 0 63 0 87 Use the 4 mm hex wrench to tighten the torch in the clip 5 16 3 Short rod low torch holder with clip The holder allows using a torch with the diameter of 16 22 mm 0 63 0 87 Use the 4 mm hex wrench to tighten the torch in the clip Part number UCW 0476 20 00 00 0 Part number UCW 0476 27 00 00 0 Part number UCW 0476 06 00...

Page 39: ...Allows using a torch with the diameter of 16 22 mm 0 63 0 87 5 16 5 Long rod torch holder with clip The holder allows using a torch with the diameter of 16 22 mm 0 63 0 87 Use the 4 mm hex wrench to tighten the torch in the clip Part number UCW 0466 04 00 00 0 Part number UCW 0466 22 00 00 0 ...

Page 40: ...ch and two M6x16 screws to tighten supports to each slot of the ring track Then use the 6 mm hex wrench and two M8x25 screws to tighten the narrow magnetic units to the supports Loosen the two levers of each support and put the ring track onto the conical workpiece Next clamp the magnetic units to the workpiece and tighten the levers Part number WSP 0523 94 00 00 0 M6x16 M8x25 ...

Page 41: ...he diameter of 28 35 mm 1 10 1 38 Allows precise adjustment of the torch angle Use the knob to adjust the vertical position Install the knob at any side by using the 2 5 mm hex wrench and the set screw To adjust the resistance of the vertical move use the 2 5 mm hex wrench to unscrew the fixing screws Then use the 2 mm hex wrench to rotate the adjusting screws Part number UCW 0475 28 00 00 0 Set s...

Page 42: ...of the vertical position of the torch by using the knob and rough adjustment of the angle 5 18 4 Precise machine torch holder for oxy fuel cutting Designed for torches with the diameter of 35 mm 1 38 equipped with a rack The holder allows adjustment of the vertical position of the torch by using the knob and precise adjustment of the angle Part number UCW 0475 29 00 00 1 Part number UCW 0475 42 00...

Page 43: ...ric RZD 0475 66 00 00 0 3 3 manifold with cut off valve metric RZD 0475 72 00 00 0 1 4 RH 2 2 manifold metric RZD 0475 64 00 00 0 2 3 manifold metric RZD 0475 63 00 00 0 2 2 manifold with cut off valve metric RZD 0475 65 00 00 0 3 3 manifold metric RZD 0475 74 00 00 0 1 4 RH 1 4 RH 1 4 RH 1 4 RH 1 4 RH 1 4 RH 1 4 RH 3 8 LH 3 8 LH 3 8 LH 3 8 LH 3 8 LH 3 8 LH 1 4 RH 1 4 RH 1 4 RH 1 4 RH 1 4 RH 1 4 R...

Page 44: ...0475 71 00 00 0 2 2 manifold imperial RZD 0475 68 00 00 0 2 2 manifold with cut off valve imperial RZD 0475 70 00 00 0 3 3 manifold imperial RZD 0475 73 00 00 0 9 16 RH 9 16 RH 9 16 RH 9 16 RH 9 16 RH 9 16 RH 9 16 RH 9 16 RH 9 16 LH 9 16 LH 9 16 LH 9 16 LH 9 16 LH 9 16 LH 9 16 RH 9 16 RH 9 16 RH 9 16 RH 9 16 RH 9 16 RH 9 16 LH 9 16 LH 9 16 LH 9 16 LH 9 16 LH 9 16 LH 9 16 RH 9 16 RH 9 16 RH 9 16 RH...

Page 45: ...Rail Runner LT Rail Runner LT Operator s Manual 45 6 WIRING DIAGRAM ...

Page 46: ...1 1 PWD 0466 28 00 00 0 POWER CORD 230V UK 1 1 PWD 0466 31 00 00 0 POWER CORD 230V INDIA 1 2 KBL 0466 17 00 00 0 START STOP ARC IGNITION CABLE 6 5 M 20 FT 1 3 KLC 000009 6 MM HEX WRENCH 1 4 UCW 0523 05 01 00 0 CABLE HOLDER 1 5 NKR 000121 KNURLED NUT M6 2 6 TRM 0219 06 16 00 0 CLAMP PLATE 1 7 RKJ 000036 HANDLEVER M6 32 2 8 ZSP 0475 62 00 00 0 SLIDE 1 9 PKT 0475 62 02 00 0 KNOB ASSY 1 10 PKT 000039 ...

Page 47: ...75 62 04 00 0 SELF LUBRICATING SLEEVE 25x28x12 2 19 UCW 0476 20 00 00 0 SHORT ROD TORCH HOLDER ASSY 1 20 ZRZ 0466 04 01 00 0 TORCH CLAMP ASSY 1 21 PKT 0466 04 01 10 0 KNOB 1 22 WLK 0476 20 01 00 0 SHORT ROD ASSY 1 23 TLJ 0419 04 02 03 0 INSULATION TUBE 1 24 RKJ 000036 HANDLEVER M6 32 1 25 RAM 0523 17 00 00 0 GUIDE ARM 1 26 KST 0525 11 00 00 0 CLAMPING BLOCK 1 27 RKJ 000036 HANDLEVER M6 32 2 28 RAM...

Page 48: ...nual 48 53 15 25 44 30 27 82 76 81 80 79 78 77 75 29 73 32 74 33 72 43 71 70 34 35 69 38 36 40 37 41 39 42 16 28 26 45 46 47 68 23 48 14 22 21 24 49 13 19 20 12 50 18 67 65 63 11 8 66 64 9 7 10 62 17 5 60 59 58 6 57 61 56 4 55 3 54 2 31 1 52 51 ...

Page 49: ...14 ROUND WASHER 3 2 8 23 TLJ 000023 SLEEVE M3x10 4 24 MDL 0570 80 01 00 0 ELECTRONIC MODULE 1 25 MTR 0570 01 02 00 0 MOTOR SET ASSY 1 26 WKR 000048 HEX SOCKET SET SCREW WITH FLAT POINT M5x6 1 27 SRB 000074 HEX SOCKET HEAD CAP SCREW M4x8 2 28 MTR 0570 01 02 08 0 MOTOR 1 29 WKR 000499 HEX SOCKET BUTTON HEAD SCREW M6x20 22 30 BOK 0570 01 07 00 0 RIGHT COVER ASSY 1 31 WSP 0570 01 06 02 0 HANDLE SUPPOR...

Page 50: ... HEX SOCKET BUTTON HEAD SCREW M5x10 4 65 WPS 0475 62 03 00 0 KEY 2 66 TLJ 000069 SELF LUBRICATING SLEEVE 25x28x20 2 67 WSP 0570 01 03 02 0 ARM SUPPORT 2 68 PLY 0570 01 03 01 0 FRONT PLATE 1 69 PLY 0523 01 01 07 0 BOTTOM PLATE 1 70 SRB 0341 02 10 00 0 MOUNTING SCREW 4 71 SRB 000310 HEX SOCKET HEAD CAP SCREW M3x10 4 72 WPS 0341 02 01 10 0 KEY 1 73 WKR 000012 HEX SOCKET SET SCREW WITH DOG POINT M4x6 ...

Page 51: ...ponsibility that Rail Runner LT Welding Carriage is manufactured in accordance with the following standards EN 12100 EN 60204 1 EN 60974 10 and satisfies safety regulations of the guidelines 2014 30 EC 2014 35 EC 2006 42 EC Person authorized to compile the technical file Marek Siergiej ul Elewatorska 23 1 15 620 Białystok Białystok 15 February 2018 ___________________________ Marek Siergiej CEO ...

Page 52: ...ne control card Rail Runner LT Welding Carriage Serial number Electric test Type of test Result Name of tester Insulation electrical strength test 1000 V 50 Hz Date Continuity test of the protective earth system Ω Signature Quality control Adjustments inspections Quality control ...

Page 53: ...rkmanship under normal use for a period of 12 months from the date of sale This warranty does not cover rollers as well as damage or wear that arise from misuse accident tempering or any other causes not related to defects in workmanship or material Date of production Serial number Date of sale Signature of seller 1 00 18 May 2018 WE RESERVE THE RIGHT TO MAKE CHANGES IN THIS MANUAL WITHOUT NOTICE ...

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