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Summary of Contents for SteelMax Rail Runner
- 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...
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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 track ....................9 3.2. -
Page 3: General Information
1. GENERAL INFORMATION 1.1. Application The Rail Runner is a track carriage designed to make butt and fillet welds with or without oscillation by using MIG/MAG torches. The track is fixed by using magnetic units to ferromagnetic surfaces that are flat or curved. -
Page 4: Equipment Included
1 unit 3 m (10 ft) power cord 1 unit 6.5 m (21 ft) arc ignition cable 1 unit 3 mm hex wrench 1 unit 4 mm hex wrench 1 unit – Operator’s Manual 1 unit Rail Runner Operator’s Manual... -
Page 5: Dimensions
Rail Runner 1.4. Dimensions 441 mm (17.4’’) Rail Runner Operator’s Manual... -
Page 6: Design
Left oscillation position dwell knob Center oscillation position dwell knob Travel speed knob Travel direction switch Arc ignition switch Oscillation offset knob (arm stroke) (Forward / O / Backward) (TEST / O / I) Oscillation speed knob Oscillation width knob Rail Runner Operator’s Manual... -
Page 7: Safety Precautions
(not included) to attach the leftmost and rightmost magnetic units of the track to a stable structure. To protect the carriage, attach a chain to a carrying handle. Make sure that the chains are not loose. Rail Runner Operator’s Manual... - Page 8 29. Do not leave the carriage unattended during work. 30. If you are not going to use the carriage, remove it from the work area and keep in a safe and dry place. Rail Runner 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 Operator’s Manual... - Page 10 Rail Runner Fig. 2. Removing the gap between the racks of a semi-flex track Rail Runner Operator’s Manual...
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Page 11: Assembling The Holder
Thus, to allow correct startup, install the torch holder and the cross slide so that they will not collide with the carriage side or obstacles. Fig. 3. Sample method of assembling the torch holder Rail Runner Operator’s Manual... -
Page 12: Positioning
OFF (1, Fig. 4), and then loosen the knob (2) fully. Then, put the carriage onto the track (3) so that the back rollers are in the groove (4). Fig. 4. Putting the carriage on the track Rail Runner Operator’s Manual... -
Page 13: Connecting To The Welding 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 Operator’s Manual... -
Page 14: Operating
Trapezoid is default. To weld according to the (trapezoid) triangular pattern, set all dwell times ( (straight line) to . To weld along a straight line, set to . Unit Unit set by the jumper cap (Fig. 7). Tab. 1. Configuration parameters Rail Runner Operator’s Manual... - Page 15 To stop the travel and save the values shown on the display, set the travel direction switch to ‘O’. After the work is finished, use the power switch to turn off the carriage. Then, unplug the carriage from the power source. Rail Runner Operator’s Manual...
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Page 16: Changing The Unit Of Measure
Fig. 1. Changing the unit of measure When the jumper cap connects the top and center pin, the measurement system will be metric after restart. When the jumper cap connects the center and bottom pin, the system will be imperial. Rail Runner Operator’s Manual... -
Page 17: Troubleshooting
Malfunction of the oscillator motor Contact service center for encoder or the controller. check and repair. Malfunction of the oscillator sensor. Contact service center for check and repair. Malfunction of the encoder board. Contact service center for check and repair. Rail Runner Operator’s Manual... -
Page 18: Maintenance
3. Clean the torch nozzle and replace if damaged. 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 Operator’s Manual... -
Page 19: Accessories
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 5.3. 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 Operator’s Manual... -
Page 20: Magnetic Units
75% (900 N) 80°C (176°F) 160°C (320°F) 50% (600 N) 120°C (248°F) 200°C (392°F) Use the 4 mm hex wrench to attach the unit to the tracks as shown in the figures. M6x16 M6x35 M6x20 M6x16 Rail Runner Operator’s Manual... - Page 21 75% (900 N) 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 Operator’s Manual...
- Page 22 75% (900 N) 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 spacing, use the 5 mm hex wrench and loosen four side screws. Rail Runner Operator’s Manual...
- Page 23 Use the 4 mm hex wrench to attach the unit to the tracks as shown in the figures. M6x16 M6x35 M6x16 To clamp the unit to the surface, use the 17 mm flat wrench (not included) and set the side screw to ON. Rail Runner Operator’s Manual...
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Page 24: 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 5.6. Transport attachment Allows transporting the wire feeder. Part number: PEP-0482-18-00-00-0 Rail Runner Operator’s Manual... -
Page 25: Mm Cross Slide
5.7. 76 mm cross slide Increases up-down or left-right adjustment range from 0–35 mm (0–1.38″) to 0–76 mm (0–3″). Part number: ZSP-0466-46-00-00-1 Install in place of the standard cross slide after removing four screws with the 4 mm hex wrench. Rail Runner Operator’s Manual... -
Page 26: Vacuum Track System
5.8. Vacuum track system Allows 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 separate manual. Rail Runner Operator’s Manual... -
Page 27: Torch Holders, Clamps, And Rods
Part number: UCW-0476-27-00-00-0 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 Operator’s Manual... - Page 28 Rail Runner Torch clamp 16–22 mm Part number: ZRZ-0466-04-01-00-0 Torch clip 16–22 mm Part number: ZCS-0476-06-01-00-0 Torch clamp 22–35 mm Part number: ZRZ-0466-19-00-00-0 Short rod Part number: WLK-0476-20-01-00-0 Long rod Part number: WLK-0466-04-10-00-0 Rail Runner Operator’s Manual...
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Page 29: 5-230 V Wiring Diagram
Rail Runner 6. 115–230 V WIRING DIAGRAM Rail Runner Operator’s Manual... -
Page 30: Wiring Diagram
Rail Runner 7. 42 V WIRING DIAGRAM Rail Runner Operator’s Manual... -
Page 31: 5-230 V Exploded Views And Parts List
ZCS-0476-06-01-00-0 TORCH CLIP ASSY RKJ-000036 HANDLEVER M6-32 UCW-0476-07-00-00-0 CABLE ANCHOR ASSY RAM-0482-17-01-00-0 CABLE ANCHOR ARM RKJ-000006 HANDLEVER M6-16 TRM-0219-06-16-00-0 CLAMP PLATE I NKR-000121 KNURLED NUT M6 RKJ-000036 HANDLEVER M6-32 TLJ-0419-04-02-03-0 INSULATION SLEEVE KST-0476-07-01-00-0 ANCHOR CLAMPING BLOCK Rail Runner Operator’s Manual... - Page 32 Rail Runner Rail Runner Operator’s Manual...
- Page 33 PRS-000022 INTERNAL RETAINING RING 32w WKR-000012 HEX SOCKET SET SCREW WITH DOG POINT M4x6 LOZ-000062 BALL BEARING 12x32x10 LOZ-000038 BALL BEARING 12x28x8 SRB-000078 HEX SOCKET HEAD CAP SCREW M5x12 SRB-000083 HEX SOCKET HEAD CAP SCREW M5x16 Rail Runner Operator’s Manual...
- Page 34 ZCS-0482-12-04-00-0 CAM CLAMP ASSY ZDR-0482-12-05-00-0 BUMPER PDK-000017 ROUND WASHER 5.3 WKR-000137 HEX SOCKET COUNTERSUNK HEAD SCREW M5x20 PDK-000022 ROUND WASHER 8.4 SPR-000012 DISC SPRING 8.2x16x0.6 TLJ-000048 SLIDE SLEEVE 8x10x12 SRB-000075 HEX SOCKET HEAD CAP SCREW M5x10 Rail Runner Operator’s Manual...
- Page 35 EXTERNAL TOOTH LOCK WASHER 4.3 PNK-000026 LEVER SWITCH 641 H3 WKR-000152 CROSS RECESSED COUNTERSUNK HEAD SCREW M4x16 WKR-000385 HEX SOCKET BUTTON HEAD SCREW M3x8 WKR-000092 HEX SOCKET BUTTON HEAD SCREW M4x10 * not shown in the drawing Rail Runner Operator’s Manual...
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Page 36: Exploded Views And Parts List
ZCS-0476-06-01-00-0 TORCH CLIP ASSY RKJ-000036 HANDLEVER M6-32 UCW-0476-07-00-00-0 CABLE ANCHOR ASSY RAM-0482-17-01-00-0 CABLE ANCHOR ARM RKJ-000006 HANDLEVER M6-16 TRM-0219-06-16-00-0 CLAMP PLATE I NKR-000121 KNURLED NUT M6 RKJ-000036 HANDLEVER M6-32 TLJ-0419-04-02-03-0 INSULATION SLEEVE KST-0476-07-01-00-0 ANCHOR CLAMPING BLOCK Rail Runner Operator’s Manual... - Page 37 Rail Runner Rail Runner Operator’s Manual...
- Page 38 HEX SOCKET BUTTON HEAD SCREW M4x6 WPS-000082 KEY 4x4x8 PRS-000022 INTERNAL RETAINING RING 32w WKR-000012 HEX SOCKET SET SCREW WITH DOG POINT M4x6 LOZ-000062 BALL BEARING 12x32x10 LOZ-000038 BALL BEARING 12x28x8 SRB-000078 HEX SOCKET HEAD CAP SCREW M5x12 Rail Runner Operator’s Manual...
- Page 39 RESISTIVE BAR ASSY LST-0482-12-03-00-0 PRESSURE BAR ASSY ZCS-0482-12-04-00-0 CAM CLAMP ASSY ZDR-0482-12-05-00-0 BUMPER PDK-000017 ROUND WASHER 5.3 WKR-000137 HEX SOCKET COUNTERSUNK HEAD SCREW M5x20 PDK-000022 ROUND WASHER 8.4 SPR-000012 DISC SPRING 8.2x16x0.6 TLJ-000048 SLIDE SLEEVE 8x10x12 Rail Runner Operator’s Manual...
- Page 40 EXTERNAL TOOTH LOCK WASHER 4.3 PNK-000026 LEVER SWITCH 641 H/3 WKR-000152 CROSS RECESSED COUNTERSUNK HEAD SCREW M4x16 WKR-000385 HEX SOCKET BUTTON HEAD SCREW M3x8 WKR-000092 HEX SOCKET BUTTON HEAD SCREW M4x10 * not shown in the drawing Rail Runner Operator’s Manual...
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Page 41: Declaration Of Conformity
Declaration of Conformity PROMOTECH sp. z o.o. ul. Elewatorska 23/1 15-620 Białystok Poland We declare with full responsibility that: Rail Runner Welding Carriage is manufactured in accordance with the following standards: • EN 50144-1 • EN 60974-10 and satisfies safety regulations of the guidelines: 2004/108/EC, 2006/95/EC, 2006/42/EC. -
Page 42: Warranty Card
WARRANTY CARD No..................in the name of Manufacturer warrants the Rail Runner 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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