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Summary of Contents for SteelMax Rail Runner LT
- Page 1 The tools of innovation. OPERATOR’S MANUAL WELDING CARRIAGE 112 Inverness Circle East Suite F Englewood, CO 80112 1– 87STEELMAX, FAX 303 – 690 – 9172 www.steelmax.com sales@steelmax.com...
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Page 2: Table Of Contents
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. -
Page 3: General Information
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. -
Page 4: Equipment Included
Rail Runner LT 1.3. Equipment included Carriage 1 unit Cardboard box 1 unit 6 mm hex wrench 1 unit 3 m (10 ft) power cord 1 unit – Operator’s Manual 1 unit Rail Runner LT – Operator’s Manual... -
Page 5: Dimensions
Rail Runner LT 1.4. Dimensions 334 mm (13.1″) Rail Runner LT – Operator’s Manual... -
Page 6: Design
Pressing lever (pressing Install bracket Drive gear rollers are loose in this position) Display Travel speed knob Power switch Travel direction switch (Forward / O / Backward) Arc ignition switch (I / O / TEST) Rail Runner LT – Operator’s Manual... -
Page 7: Safety Precautions
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. Rail Runner LT – Operator’s Manual... - Page 8 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. Rail Runner LT – Operator’s Manual...
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Page 9: Startup And Operation
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 LT – Operator’s Manual... - Page 10 Rail Runner LT Fig. 2. Removing the gap between the racks of a semi-flexible track Rail Runner LT – Operator’s Manual...
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Page 11: Assembling The Ring Track
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. Rail Runner LT – Operator’s Manual... - Page 12 (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 Rail Runner LT – Operator’s Manual...
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Page 13: Positioning On A Straight Track
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). Gear retracted Install bracket Fig. 6. Putting the carriage on a straight track Rail Runner LT – Operator’s Manual... - Page 14 (4). However, do not tighten the knob with too much force. Keep some backlash between the gear and rack. Not engaged × Engaged ✓ Fig. 7. Engaging the carriage with the track Rail Runner LT – Operator’s Manual...
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Page 15: Positioning On A Curved Track
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 Rail Runner LT – Operator’s Manual... -
Page 16: Preparing
Rail Runner LT 3.5. Preparing Install an optional welding/cutting set as shown in Fig. 9. MIG/MAG welding SAW welding Rail Runner LT – Operator’s Manual... - Page 17 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. Rail Runner LT – Operator’s Manual...
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Page 18: Connecting To The Welding Or 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. Rail Runner LT – Operator’s Manual... -
Page 19: Operating
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. Rail Runner LT – Operator’s Manual... -
Page 20: Adjusting The Pressure Of Rollers
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 the pressure of rollers Rail Runner LT – Operator’s Manual... -
Page 21: Troubleshooting
Adjust the position of the cables so the carriage. that they do not block the travel. Remove other elements that block the carriage or the drive gear. If this message still shows, contact service center for check and repair. Rail Runner LT – Operator’s Manual... -
Page 22: Maintenance
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. Rail Runner LT – Operator’s Manual... -
Page 23: Accessories
Rack holder 1 unit Clamping block with levers 1 unit Cutting torch clamp 28–35 mm (1.10–1.38″) 1 unit Short rod 1 unit Cable anchor 1 unit 6.5 m (21 ft) arc ignition cable 1 unit Rail Runner LT – Operator’s Manual... -
Page 24: Oxy-Fuel Cutting Set
4 mm hex wrench 1 unit 5.4. Plasma cutting set Part number: ZST-0570-03-02-00-0 Precise torch holder 28–35 mm (1.10–1.38″) 1 unit Cable anchor 1 unit 6.5 m (21 ft) arc ignition cable 1 unit Rail Runner LT – Operator’s Manual... -
Page 25: Semi-Flexible Track
Allows guiding the carriage along a straight line. The length of a single rail is 2 m (6.5 ft). Part number: PRW-0482-47-00-00-0 5.7. Rack adjustment tool Removes the clearance between the racks of two semi-flexible rails that are put on a curve. Part number: PKT-0341-13-00-00-0 Rail Runner LT – Operator’s Manual... -
Page 26: Magnetic Units
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. M6x35 M6x16 M6x20 M6x16 Rail Runner LT – Operator’s Manual... - Page 27 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 Part number (bracket for semi-flexible track): (bracket for rigid track): DYS-0482-19-00-00-0 DYS-0482-21-00-00-0 Rail Runner LT – Operator’s Manual...
- Page 28 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 Part number (bracket for semi-flexible track): (bracket for rigid track): DYS-0482-19-00-00-0 DYS-0482-21-00-00-0 Rail Runner LT – Operator’s Manual...
- Page 29 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 set the side screw to ON. Rail Runner LT – Operator’s Manual...
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Page 30: 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 Rail Runner LT – Operator’s Manual... -
Page 31: 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. Rail Runner LT – Operator’s Manual... -
Page 32: Ring Tracks
TRO-0523-23-00-00-0 TRO-0523-24-00-00-0 TRO-0523-25-00-00-0 TRO-0523-26-00-00-0 TRO-0523-22-00-00-0 TRO-0523-28-00-00-0 TRO-0523-29-00-00-0 TRO-0523-30-00-00-0 TRO-0523-31-00-00-0 TRO-0523-32-00-00-0 TRO-0523-33-00-00-0 1000 TRO-0523-34-00-00-0 1000 1050 TRO-0523-35-00-00-0 1050 1100 TRO-0523-36-00-00-0 1100 1150 TRO-0523-37-00-00-0 1150 1200 TRO-0523-38-00-00-0 1200 1250 TRO-0523-39-00-00-0 1250 1300 TRO-0523-40-00-00-0 1300 1350 TRO-0523-41-00-00-0 Rail Runner LT – Operator’s Manual... - Page 33 TRO-0523-64-00-00-0 2500 2550 TRO-0523-65-00-00-0 2550 2600 TRO-0523-66-00-00-0 2600 2650 TRO-0523-67-00-00-0 2650 2700 TRO-0523-68-00-00-0 2700 2750 TRO-0523-69-00-00-0 2750 2800 TRO-0523-70-00-00-0 2800 2850 TRO-0523-71-00-00-0 2850 2900 TRO-0523-72-00-00-0 2900 2950 TRO-0523-73-00-00-0 2950 3000 TRO-0523-74-00-00-0 3000 3050 TRO-0523-75-00-00-0 Rail Runner LT – Operator’s Manual...
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Page 34: Ring Track Supports
Rail Runner LT 5.12. Ring track supports 5.12.1. Ring track support with bolts Part number: WSP-0523-14-02-00-0 5.12.2. Ring track support with plastic feet Part number: WSP-0523-14-11-00-0 5.12.3. Ring track support with magnets Part number: WSP-0523-14-12-00-0 Rail Runner LT – Operator’s Manual... -
Page 35: Rack
RAM-0475-07-03-00-0 (700 mm, 28″) RAM-0475-23-00-00-0 (1000 mm, 39″) 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). Rail Runner LT – Operator’s Manual... -
Page 36: Torch Clamps
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. Part number: ZCS-0476-06-01-00-0 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 Rail Runner LT – Operator’s Manual... -
Page 37: Rods
Rail Runner LT 5.15. Rods 5.15.1. Short rod Provides a 120 mm (4.7″) reach. Part number: WLK-0476-20-01-00-0 5.15.2. Long rod Provides a 240 mm (9.4″) reach. Part number: WLK-0466-04-10-00-0 Rail Runner LT – Operator’s Manual... -
Page 38: Torch Holders
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-0476-06-00-00-0 Rail Runner LT – Operator’s Manual... - Page 39 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-0466-22-00-00-0 Rail Runner LT – Operator’s Manual...
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Page 40: Pivoting Support
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 Rail Runner LT – Operator’s Manual... -
Page 41: Cutting Torch Holders
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. Set screw Adjusting screws Fixing screws Part number: UCW-0475-08-00-00-0 Rail Runner LT – Operator’s Manual... - Page 42 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-0475-42-00-00-1 Rail Runner LT – Operator’s Manual...
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Page 43: Gas Manifold (For Oxy-Fuel Cutting)
1/4″ RH 3/8″ LH 1/4″ RH 3/8″ LH 2/2 manifold with cut-off valve 1/4″ RH 3/8″ LH (metric): 1/4″ RH RZD-0475-65-00-00-0 3/3 manifold with cut-off valve 2/3 manifold with cut-off valve (metric): (metric): RZD-0475-72-00-00-0 RZD-0475-66-00-00-0 Rail Runner LT – Operator’s Manual... - Page 44 9/16″ RH 9/16″ LH 9/16″ RH 9/16″ LH 9/16″ RH 9/16″ LH 9/16″ RH 2/2 manifold with cut-off valve (imperial): 3/3 manifold with cut-off valve 2/3 manifold with cut-off valve RZD-0475-70-00-00-0 (imperial): (imperial): RZD-0475-71-00-00-0 RZD-0475-69-00-00-0 Rail Runner LT – Operator’s Manual...
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Page 45: Wiring Diagram
Rail Runner LT 6. WIRING DIAGRAM Rail Runner LT – Operator’s Manual... -
Page 46: Exploded Views And Parts List
6 MM HEX WRENCH UCW-0523-05-01-00-0 CABLE HOLDER NKR-000121 KNURLED NUT M6 TRM-0219-06-16-00-0 CLAMP PLATE RKJ-000036 HANDLEVER M6-32 ZSP-0475-62-00-00-0 SLIDE PKT-0475-62-02-00-0 KNOB ASSY PKT-000039 KNOB D50xM10 ZLC-0475-62-02-01-0 THREAD JOINT OSK-0475-62-02-02-0 PIVOT PIN KOL-0475-62-02-03-0 GEAR z16 Rail Runner LT – Operator’s Manual... - Page 47 UCW-0476-20-00-00-0 SHORT ROD TORCH HOLDER ASSY ZRZ-0466-04-01-00-0 TORCH CLAMP ASSY PKT-0466-04-01-10-0 KNOB WLK-0476-20-01-00-0 SHORT ROD ASSY TLJ-0419-04-02-03-0 INSULATION TUBE RKJ-000036 HANDLEVER M6-32 RAM-0523-17-00-00-0 GUIDE ARM KST-0525-11-00-00-0 CLAMPING BLOCK RKJ-000036 HANDLEVER M6-32 RAM-0525-07-00-00-0 GEARED RACK 540 MM (21″) Rail Runner LT – Operator’s Manual...
- Page 48 Rail Runner LT Rail Runner LT – Operator’s Manual...
- Page 49 HEX SOCKET HEAD CAP SCREW M8x40 BOK-0570-01-06-00-0 LEFT COVER ASSY SRB-0523-01-03-03-0 FEED SCREW SPR-000010 DISC SPRING 6.2x12.5x0.6 PDK-000136 SMALL ROUND WASHER 6.4 PLY-0570-01-06-01-0 LEFT COVER PLATE PKT-0341-02-08-00-0 KNOB NKR-000017 HEX NUT M6 PKT-000038 STAR KNOB D63 Rail Runner LT – Operator’s Manual...
- Page 50 GEAR z14 PDK-000022 ROUND WASHER 8.4 RLK-0341-01-02-00-0 PRESSURE ROLLER ASSY LOZ-000053 BALL BEARING 8x22x7 PDK-000173 WASHER 8x14x0.1 PDK-000174 WASHER 8x14x0.1 RLK-0341-01-02-01-0 PRESSURE ROLLER PRS-000014 INTERNAL RETAINING RING 22w SRB-000030 FULL THREAD HEX HEAD SCREW M8x30 Rail Runner LT – Operator’s Manual...
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Page 51: Declaration Of Conformity
• 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 Rail Runner LT – Operator’s Manual... -
Page 52: Quality Certificate
Type of test Result Name of tester Insulation electrical strength test ........(1000 V, 50 Hz) Date Ω …........... Continuity test of the protective earth system Signature Quality control ..........Adjustments, inspections Quality control ..........Rail Runner LT – Operator’s Manual... -
Page 53: Warranty Card
WARRANTY CARD No..................in the name of Manufacturer warrants the Rail Runner LT Welding Carriage to be free of defects in material and workmanship 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.
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