THERMACUT EX-TRACK MA-1 Operating Instructions Manual

Portable flame cutting machine

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Portable Flame Cutting Machine

Operating Instructions – EX-0-902-003/N-23778 –CE

Revision 1, 8

November, 2023

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Summary of Contents for THERMACUT EX-TRACK MA-1

Page 1 Portable Flame Cutting Machine Operating Instructions – EX-0-902-003/N-23778 –CE Revision 1, 8 November, 2023...
Page 2: Table Of Contents
® EX-TRACK MA-1/MA-2 Table of contents Identification ............... EN-4 Labeling..................... EN-4 Identification plates................EN-4 Signs and symbols used..............EN-4 Classification of the warnings ............EN-5 Safety................EN-5 Designated use................. EN-5 Obligations of the operator ............EN-6 Product-specific safety instructions..........EN-6 Safety instructions for the cutter.............
Page 3 ® EX-TRACK MA-1/MA-2 Wiring diagram ............EN-22 Parts list and exploded views EX-TRACK®MA-1 and MA-2 ........EN-23 Cutting data .............. EN-34 Ordering number ............EN-34 EN - 3...
Page 4: Identification
® 1 Identification EX-TRACK MA-1/MA-2 Identification ® The EX-TRACK MA-1/MA-2 is a portable gas cutter for cutting stripes or ® circles. The EX-TRACK MA-1/MA-2 is equipped for straight line, bevel, and optional circle cutting. It has to be operated only with original consumables and maintenance parts.
Page 5: Classification Of The Warnings
® EX-TRACK MA-1/MA-2 2 Safety Classification of the warnings The warnings are divided into four different categories and are indicated prior to potentially dangerous work steps. The following signal words are used depending on the type of hazard: DANGER Describes an imminent threatening danger. If not avoided, it may cause severe injury or death.
Page 6: Obligations Of The Operator
 Keep untrained persons out of the work area. ® ®  Each time the EX-TRACK MA-1/MA-2 is opened, have Thermacut another authorized specialist perform a safety inspection in accordance with IEC 60974 Part 4: “Periodic inspection and testing”. Product-specific safety instructions ®...
Page 7: Safety Instructions For The Cutter
® EX-TRACK MA-1/MA-2 2 Safety Safety instructions for the cutter  Ensure that the hoses are not damaged, for example, by being driven over, crushed, or torn.  Check the hoses for damage and wear at regular intervals.  Bundle together the hose and cable with a tape, and place them on the opposite side of the flame so as to avoid damage by spatter, or dross.
Page 8: Scope Of Delivery
® 3 Scope of delivery EX-TRACK MA-1/MA-2 Scope of delivery The following components are included in the scope of supply: ® EX-TRACK MA-1: ® — 1 x EX-TRACK MA-1 — 1 x Torch holder assembly — 1 x Fuel gas nut —...
Page 9: Ex-Track
® EX-TRACK MA-1/MA-2 3 Scope of delivery Goods-in inspection  Check for order completeness by checking the delivery note.  Check the delivered goods for damage (visual inspection). Claim process  If goods are damaged, notify the final carrier immediately. ...
Page 10: Product Description
® 4 Product description EX-TRACK MA-1/MA-2 Product description Assembly and use The pipe cutter consists of the following components: Fig. 2 Control elements and connections A Holder flange I Forward/Reverse switch B Hoses J Rail C Rack holder K Idle wheel D Horizontal gear rack L Clutch lever E Guide wheel (under carriage)
Page 11: Technical Data
® EX-TRACK MA-1/MA-2 4 Product description Forward/Reverse switch (I) Adjusts the direction in which the ® EX-TRACK MA-1/MA-2 travels. The neutral position is the stop position. ® Rail (J) Guides the EX-TRACK MA-1/MA-2 along the intended cut. ® Idle wheel (K) Holds the EX-TRACK MA-1/MA-2 on the rails.
Page 12: Transport And Positioning
® 5 Transport and positioning EX-TRACK MA-1/MA-2 Transport and positioning WARNING Risk of injury due to improper transport and installation ® Improper transport and installation can cause the EX-TRACK MA-1/MA-2 to tip or fall. This may result in injury.  Wear your personal protective equipment. ...
Page 13: Connecting To The Gas Supply
® ® EX-TRACK MA-1/MA-2 6 Setting up the EX-TRACK MA-1/MA-2 Connecting to the gas supply WARNING Risk of injury due to explosion The use of defective or damaged gas cylinders or hoses can cause explosions. This can result in injury. ...
Page 14: Operating The Ex-Track
® ® 7 Operating the EX-TRACK MA-1/MA-2 EX-TRACK MA-1/MA-2 ® Operating the EX-TRACK MA-1/MA-2 WARNING Risk of injury or damage due to backfire Backfires may cause serious accidents or fire. Backfires are caused by improper gas pressure.  When a backfire occurs, you should find the cause. ®...
Page 15: Positioning The Ex-Track
® ® EX-TRACK MA-1/MA-2 7 Operating the EX-TRACK MA-1/MA-2 ® Positioning the EX-TRACK MA-1/MA-2 WARNING Risk of crushing Improper assembly and disassembly of components can result in crushing of limbs.  Do not reach into the hazardous areas.  Do not catch your hands between the rails. ...
Page 16 ® ® 7 Operating the EX-TRACK MA-1/MA-2 EX-TRACK MA-1/MA-2 Open the cutting oxygen valve fully. Re-adjust the flame so it shows an orderly flow. Lower the tip to the cutting line with a distance of 8 to 10 mm between workpiece and torch.
Page 17: Circle Cutting
® ® EX-TRACK MA-1/MA-2 7 Operating the EX-TRACK MA-1/MA-2 Circle cutting For circle cutting use circle rail. 7.4.1 Cutting with circle rail A Guide wheel C Circle rail, inside groove B Idle wheel Align the idle wheel (B) to the inside groove of the rail (C) Align the guide wheel (A) to the outside groove of the rail.
Page 18: Decommissioning
® 8 Decommissioning EX-TRACK MA-1/MA-2 Decommissioning ® Disconnect the EX-TRACK MA-1/MA-2 from the oxygen supply. ® Disconnect the EX-TRACK MA-1/MA-2 from the fuel gas supply. Maintenance and cleaning Scheduled maintenance and cleaning are prerequisites for a long service life and trouble-free operation. The maintenance cycle is determined by ®...
Page 19: Faults And Troubleshooting
® EX-TRACK MA-1/MA-2 10 Faults and troubleshooting ®  Check the EX-TRACK MA-1/MA-2 for signs of cracks and exposed wires.  Check the gas hose, filter elements, and connections for leaks. Every 3 months or  Separate the reduction units from the motor 2000 hours and clean the gear box with cleaning oil.
Page 20: Carriage Faults
® 10 Faults and troubleshooting EX-TRACK MA-1/MA-2 10.3 Carriage faults Possible cause Measures Troubleshooting  Set the speed Defective speed meter. Belt or needle slipped due to loose needle adjustment knob to screw. “Low” and set the needle to the lowest scale.
Page 21: Disposal
 Observe the relevant local regulations and disposal instructions in the safety data sheets specified by the manufacturer of the consumables. 11.3 Packaging ® Thermacut has reduced the packaging to the necessary minimum. The ability to recycle packaging materials is always considered during their selection.
Page 22: Warranty
Warranty This warranty statement is an integral part of the Terms and Conditions ® (“T&C”) of Thermacut (hereinafter “Seller”) and applies to deliveries of goods under the contract concluded between the Seller and the other party to the contract as the recipient of the goods (hereinafter “Buyer”); the terms used herein have the same meaning as attributed to them in the T&C.
Page 23: Parts List And Exploded Views Ex-Track®Ma-1 And
® EX-TRACK MA-1/MA-2 14 Parts list and exploded views EX-TRACK®MA-1 and MA-2 Parts list and exploded views ® EX-TRACK MA-1 and MA-2 ® Fig. 3 Exploded view EX-TRACK MA-1, upper and middle part EN - 23...
Page 24 ® 14 Parts list and exploded views EX-TRACK®MA-1 and MA-2 EX-TRACK MA-1/MA-2 ® Fig. 4 Exploded view EX-TRACK MA-1, middle and lower part EN - 24...
Page 25 ® EX-TRACK MA-1/MA-2 14 Parts list and exploded views EX-TRACK®MA-1 and MA-2 ® Table 4 Parts list EX-TRACK MA-1 Ref. no. Position Description pcs./machine EX-0-718-000 Main device EX-0-718-001 Main top cover EX-0-718-002 Main bottom cover EX-0-718-003 Secondary heat shield EX-0-718-004 Main heat shield EX-0-718-005 Identification plate...
Page 26 ® 14 Parts list and exploded views EX-TRACK®MA-1 and MA-2 EX-TRACK MA-1/MA-2 ® Table 4 Parts list EX-TRACK MA-1 Ref. no. Position Description pcs./machine EX-0-718-037 4-10 Big drive gear EX-0-718-038 4-11 Driving worm gear EX-0-718-039 4-12 Bearing cover EX-0-718-040 4-13 Main axis EX-0-718-041 4-14...
Page 27 ® EX-TRACK MA-1/MA-2 14 Parts list and exploded views EX-TRACK®MA-1 and MA-2 ® Table 4 Parts list EX-TRACK MA-1 Ref. no. Position Description pcs./machine EX-0-718-080 Optional accessory EX-0-718-081 On/off switch EX-0-718-082 Switch box EX-0-718-083 Screw pin EX-0-718-084 M5x12 hexagon socket head cap screw EX-0-718-085 M5x12 cylindrical head screw...
Page 28 ® 14 Parts list and exploded views EX-TRACK®MA-1 and MA-2 EX-TRACK MA-1/MA-2 ® Table 4 Parts list EX-TRACK MA-1 Ref. no. Position Description pcs./machine EX-0-718-121 Ø8.5x1.2x17 mm valve needle spring EX-0-718-122 Ø6 mm steel ball EX-0-718-123 16x2.5 O-ring EX-0-718-124 M6x8 cap head bolt EX-0-718-125 Ø4 mm flat washer EN - 28...
Page 29 ® EX-TRACK MA-1/MA-2 14 Parts list and exploded views EX-TRACK®MA-1 and MA-2 ® Fig. 5 Exploded view EX-TRACK MA-2, upper and middle part EN - 29...
Page 30 ® 14 Parts list and exploded views EX-TRACK®MA-1 and MA-2 EX-TRACK MA-1/MA-2 ® Fig. 6 Exploded view EX-TRACK MA-2, middle and lower part EN - 30...
Page 31 ® EX-TRACK MA-1/MA-2 14 Parts list and exploded views EX-TRACK®MA-1 and MA-2 ® Table 5 Parts list EX-TRACK MA-2 Ref. no. Position Description pcs./machine EX-0-718-000 Main device EX-0-718-001 Main top cover EX-0-718-002 Main bottom cover EX-0-718-003 Secondary heat shield EX-0-718-004 Main heat shield EX-0-718-126 1-5-1...
Page 32 ® 14 Parts list and exploded views EX-TRACK®MA-1 and MA-2 EX-TRACK MA-1/MA-2 ® Table 5 Parts list EX-TRACK MA-2 Ref. no. Position Description pcs./machine EX-0-718-031 Reduction box EX-0-718-032 Cone wheel EX-0-718-033 Drive wheel sleeve EX-0-718-034 Drive wheel seat EX-0-718-035 Passive friction wheel EX-0-718-036 Drive gear EX-0-718-037...
Page 33 ® EX-TRACK MA-1/MA-2 14 Parts list and exploded views EX-TRACK®MA-1 and MA-2 ® Table 5 Parts list EX-TRACK MA-2 Ref. no. Position Description pcs./machine EX-0-718-074 7-12 Motion transfer base EX-0-718-075 7-13 Big spring screw EX-0-718-076 7-14 Spring screw EX-0-718-077 7-15 Screw pin EX-0-718-078 7-16...
Page 34: Cutting Data
6500 350 – 280 EX-0-708-022 60 – 90 8 – 10 1860 11000 300 – 240 Ordering number Table 6 Ordering numbers Part no. Item EX-0-704-002 EX-TRACK MA-1/240 V AC/CE/1-OXY/straight cutter EX-0-704-003 EX-TRACK MA-2/240 V AC/CE/2-OXY/straight cutter EN - 34...
Page 35: Addresses And Contacts
Tel.: +385 53 882 622 Fax.: +49 (0)2736 29 49 11-77 E-mail: thermacut@gs.t-com.hr E-mail: info@thermacut.de www.thermacut.hr www.thermacut.de POLAND FRANCE THERMACUT-POLAND SP. Z O.O. THERMACUT FRANCE ul. Stawowa 20 6 Rue des Frères Lumière 43-400 Cieszyn 67201 Eckbolsheim POLAND Tel.:+33 3 88 76 58 75 Tel.: +48 33 852 13 34...
Page 36 E-mail: ac@binzel.se, E-mail: info@binzel.fi ket@binzel.se www.thermacut.net www.thermacut.net BELARUS SLOVAKIA IOOO „ABICOR BINZEL Technics“ THERMACUT SLOVAKIA, s.r.o. ul. Timirjazeva 97-10 Priemyselná ulica 1239 BY-220020 Minsk 931 01 Šamorín ?el.: +375 29 5 800 300 Tel.: +421 31 591 0121 E-mail: info@thermacut.by +421 903 644 954 www.thermacut.by...
Page 37 E-mail: ezio.minh@mnt.com.vn E-mail: info@thermacut.com.kz www.thermacut.net www.thermacut.kz SOUTH KOREA JAPAN Abicor Binzel Korea Ltd. Thermacut Japan Ltd. #A-101, 263, Gaejwa-ro 3F Shin-Osaka Hankyu Building Guemjeong-gu 1-1-1, Miyahara, Yodogawa-ku, Osaka Busan 532-0003 Japan Tel.: 0082 (31) 732 6065 / 6066 / 6067 Mob.: +81 (0)80 4738 9752...
Page 38: Revision History
Revision history You can find the latest version of the operator manual on our website: www.ex-track.com.

This manual is also suitable for:

Ex-track ma-2 Ex-0-704-002 Ex-0-704-003