SteelMax Rail Runner LT Operator's Manual

Welding carriage
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The tools of innovation.
OPERATOR'S MANUAL
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WELDING CARRIAGE
15335 E. Freemont Drive, Centennial, CO 80112
1– 87STEELMAX, FAX 303 – 690 – 9172
www.steelmax.com sales@steelmax.com
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  • Page 1 The tools of innovation. OPERATOR’S MANUAL WELDING CARRIAGE 15335 E. Freemont Drive, Centennial, CO 80112 1– 87STEELMAX, FAX 303 – 690 – 9172 www.steelmax.com sales@steelmax.com...
  • 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 hi-flex, semi-flex, or rigid track............9 3.2.
  • 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. 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

    1.3. Equipment included Carriage with a 540 mm (21″) rack 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 roll- Install bracket Drive gear ers are loose in this position) Display Speed knob Power switch Arc ignition switch (I / O / TEST) Direction switch (Forward / O / Backward) Rail Runner LT – Operator’s Manual...
  • Page 7: Safety Precautions

    22. Use the rigid track only on flat surfaces. 23. 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 hi-flex, Rail Runner LT – Operator’s Manual...
  • Page 8 30. Do not leave the carriage unattended during work. 31. If you are not going to use the carriage, remove it from the worksite and keep in a safe and dry place. Rail Runner LT – Operator’s Manual...
  • Page 9: Startup And Operation

    (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 Rail Runner LT – Operator’s Manual...
  • Page 10 (4) to remove the gap (5) between the racks. Then, tighten the leftmost screw and the rightmost screw of each rack (2). Fig. 2. Removing the gap between the racks of a semi-flex track Rail Runner LT – Operator’s Manual...
  • 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...
  • 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 mounting brackets are on the rail (4, 5). Gear retracted Mounting bracket Mounting bracket Fig. 6. Putting the carriage on a straight track Rail Runner LT – Operator’s Manual...
  • Page 14 (6) to make sure that there is a backlash. Do not tighten the knob with too much force (7). INCORRECT CORRECT INCORRECT ✓ Gear not engaged. Knob tightened too much. No backlash. Fig. 7. Installing the carriage on the track Rail Runner LT – Operator’s Manual...
  • Page 15: Positioning On A Curved Track

    Then, tighten the screws (1) and use the knob (4) to engage the gear with the rack as described in “Positioning on a straight track”. 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. Make sure that the chains are not loose. Connect the carriage to the power source. Then, put the torch and torch cables into the holders. Rail Runner LT – Operator’s Manual...
  • 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 ena- ble 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 direction switch to ‘O’. After the work is finished, use the power switch to turn off the carriage. Then, un- plug the carriage from the power source. Rail Runner LT – Operator’s Manual...
  • Page 20: Adjusting The Pressure Of Rollers

    If the carriage moves 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

    Disengage the gear from the rack and engage them again as described in “Positioning on a straight track”. If this message still shows, contact service center for check and repair. Rail Runner LT – Operator’s Manual...
  • Page 22: Maintenance

    Each month: 1. Make sure that the knobs and the switches work as intended. Replace if they are loose or damaged. 2. Examine cables and cords, and 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: Hi-Flex Track

    If you need to use more units, use narrow magnetic units. Part number (rail): TRO-0673-00-00-00-0 Part number (rollers for hi-flex track): ZSP-0673-07-00-00-0 Use the 13 mm flat wrench to remove the standard rollers and install the rollers for hi- flex track. Rail Runner LT – Operator’s Manual...
  • Page 26: Semi-Flex 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 5.8. Rack adjustment tool Removes the clearance between the racks of two semi-flex rails that are put on a curve. Part number: PKT-0341-13-00-00-0 Rail Runner LT – Operator’s Manual...
  • Page 27: Magnetic Units

    75% (900 N) 80°C (176°F) 75% (900 N) 50% (600 N) 50% (600 N) 120°C (248°F) Use the 4 mm hex wrench to attach the unit to the tracks as shown in the figures. Rail Runner LT – Operator’s Manual...
  • Page 28 Rail Runner LT M6x16 M6x16 M6x20 M6x20 M6x35 M6x16 Rail Runner LT – Operator’s Manual...
  • Page 29 80°C (176°F) 50% (600 N) 120°C (248°F) 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. Rail Runner LT – Operator’s Manual...
  • Page 30 50% (600 N) 120°C (248°F) Install the unit in the same way as the magnetic unit is installed. To adjust the spac- ing, use the 5 mm hex wrench and loosen four side screws. Rail Runner LT – Operator’s Manual...
  • Page 31 20°C (68°F) 75% (750 N) 80°C (176°F) 50% (500 N) 120°C (248°F) Use the 4 mm hex wrench to attach the unit to the tracks as shown in the figures. M6x16 M6x16 M6x16 M6x16 Rail Runner LT – Operator’s Manual...
  • Page 32: Semi-Flex Track Support

    5.10. Semi-flex track support Allows supporting a semi-flex track by using the support instead of a magnetic unit or narrow magnetic unit. Use the 4 mm hex wrench to attach the support. Part number: WSP-0523-12-01-00-1 M6x16 Rail Runner LT – Operator’s Manual...
  • Page 33: Vacuum Track System

    Dedicated to clamping the track to non-ferromagnetic surfaces. Part number (vacuum pump with safety reservoir): AGR-0541-24-10-00-0 (115 V US) AGR-0541-24-20-00-0 (230 V CEE) Other parts of the system are described in a related manual. Rail Runner LT – Operator’s Manual...
  • Page 34: Ring Tracks

    Min. Max. [mm] [mm] TRO-0523-14-00-00-0 TRO-0523-78-00-00-0 TRO-0523-20-00-00-0 TRO-0523-21-00-00-0 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 Rail Runner LT – Operator’s Manual...
  • Page 35 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...
  • Page 36: Ring Track Supports And Bracket

    5.13. Ring track supports and bracket Ring track support with bolts Part number: WSP-0523-14-02-00-0 Ring track support with plastic feet Part number: WSP-0523-14-11-00-0 Ring track support with magnets Part number: WSP-0523-14-12-00-0 Ring track bracket Part number: DYS-0523-14-14-00-0 Rail Runner LT – Operator’s Manual...
  • Page 37: 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 put the rack into the carriage (3). Rail Runner LT – Operator’s Manual...
  • Page 38: Torch Holders, Clamps, And Rods

    Short low rod torch holder with clip 16–22 mm Part number: UCW-0476-06-00-00-0 Long rod torch holder with clamp 16–22 mm Part number: UCW-0466-04-00-00-0 Long rod torch holder with clip 16–22 mm Part number: UCW-0466-22-00-00-0 Rail Runner LT – Operator’s Manual...
  • Page 39 ZCS-0476-06-01-00-0 Torch clamp 22–35 mm Part number: ZRZ-0466-19-00-00-0 Torch clamp 28–35 mm for SAW welding Part number: ZCS-0475-28-10-00-0 Short rod Part number: WLK-0476-20-01-00-0 Long rod Part number: WLK-0466-04-10-00-0 Rod for cutting Part number: KLM-0236-00-16-00-0 Rail Runner LT – Operator’s Manual...
  • Page 40: Cutting Torch Holders

    To adjust the resistance of the vertical travel, use the 2.5 mm hex wrench to re- move 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 41 For torches with the diameter of 35 mm (1.38″) that have a rack. 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...
  • Page 42: Gas Manifold (For Oxy-Fuel Cutting)

    3/8″ LH 1/4″ RH 3/8″ LH 1/4″ RH 2/2 manifold with cut-off valve (met- 3/8″ LH ric): 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 43 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 (im- perial): 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...
  • Page 44: Wiring Diagram

    Rail Runner LT 6. WIRING DIAGRAM Rail Runner LT – Operator’s Manual...
  • Page 45: Exploded Views And Parts List

    Rail Runner LT 7. EXPLODED VIEWS AND PARTS LIST ITEM PART NUMBER DESCRIPTION Q-TY PWD-0466-16-00-00-0 POWER CORD 115 V (US) KLC-000009 6 MM HEX WRENCH RAM-0525-07-00-00-0 RACK 540 MM (21″) Rail Runner LT – Operator’s Manual...
  • Page 46 Rail Runner LT Rail Runner LT – Operator’s Manual...
  • Page 47 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 48 BALL BEARING 8x22x7 PDK-000173 WASHER 8x14x1 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 PDK-000166 EXTERNAL TOOTH LOCK WASHER 4.3 PDK-000266 EXTERNAL TOOTH LOCK WASHER 6.4 Rail Runner LT – Operator’s Manual...
  • Page 49: Declaration Of Conformity

    • EN 60974-10 and satisfies 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, Poland Białystok, 15 February 2018 ___________________________ Marek Siergiej Rail Runner LT – Operator’s Manual...
  • Page 50: 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 workman- ship under normal use for a period of 12 months from the date of sale.

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