ESAB Tramtrac II Instruction manual / Spare parts list (Replacement parts)

GB

Tramtrac

t

II

Instruction manual

Valid for serial no. 06470460 231 001 GB 2008--04--24

ESAB AB, Welding Equipment, SE--695 81 Laxå, Sweden, gives its unreserved guarantee that

L

automatic welding machine TramtractII from serial number 0647 complies with standard
EN 12100--2 and EN 60204--1, in accordance with the requirements of directive (73/27/EEC) and with
standard EN 61000--6--2 and also EN 61000--6--3, in accordance with the requirements of directive
(89/336/EEC).

-- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -----------------------------------­axå 2006--12--21

Kent Eimbrodt
Global Director
ESAB AB, Welding Equipment
SE--695 81 LAXÅ
SWEDEN Tel: + 46 584 81000 Fax: + 46 584 411721

DECLARATION OF CONFORMITY

-- 2 --

1SAFETY 4...........................................................

2 INTRODUCTION 6...................................................

2.1 General 6..................................................................

2.2 Technical data 7............................................................

3 INSTALLATION 8....................................................

3.1 General 8..................................................................

4 OPERATION 10.......................................................

4.1 General 10..................................................................

4.2 Handling 10.................................................................

5 MAINTENANCE 11....................................................

5.1 General 11..................................................................

5.2 Daily 11.....................................................................

5.3 As necessary 11.............................................................

6 ACCESSORIES 11....................................................

7 ORDERING OF SP ARE P ARTS 11......................................

DIMENSION DRAWING 12................................................

DIAGRAM 13............................................................

SPARE PARTS LIST 15...................................................

Rights reserved to alter specifications without notice.

TOCe

-- 3 --

GB

1SAFETY

Users of ESAB welding equipment have the ultimate responsibility for ensuring that anyone who
works on or near the equipment observes all the relevant safety precautions. Safety precautions
must meet the requirements that apply to this type of welding equipment. The following recommen­dations should be observed in addition to the standard regulations that apply to the workplace.

All work must be carried out by trained personnel well--acquainted with the operation of the welding
equipment. Incorrect operation of the equipment may lead to hazardous situations which can result
in injury to the operator and damage to the equipment.

1. Anyone who uses the welding equipment must be familiar with:

S its operation
S location of emergency stops
S its function
S relevant safety precautions
S welding

2. The operator must ensure that:
S no unauthorised person is stationed within the working area of the equipment when it is

started up.

S no--one is unprotected when the arc is struck

3. The workplace must:

S be suitable for the purpose
S be free from draughts

4. Personal safety equipment
S Always wear recommended personal safety equipment, such as safety glasses, flame--proof

clothing, safety gloves.

S Do not wear loose--fitting items, such as scarves, bracelets, rings, etc., which could become

trapped or cause burns.

5. General precautions

S Make sure the return cable is connected securely.
S Work on high voltage equipment may only be carried out by a qualified electrician.
S Appropriate fire extinquishing equipment must be clearly marked and close at hand.
S Lubrication and maintenance must not be carried out on the equipment during operation.

SafE

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GB

WARNING

ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE PRECAU­TIONS WHEN WELDING. ASK FOR YOUR EMPLOYER’S SAFETY PRACTICES WHICH SHOULD BE
BASED ON MANUFACTURERS’ HAZARD DATA.

ELECTRIC SHOCK -- Can kill

S Install and earth the welding unit in accordance with applicable standards.
S Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.
S Insulate yourself from earth and the workpiece.
S Ensure your working stance is safe.

FUMES AND GASES -- Can be dangerous to health

S Keep your head out of the fumes.
S Use ventilation, extraction at the arc, or both, to take fumes and gases away from your breathing zone

and the general area.

ARC RAYS -- Can injure eyes and burn skin.

S Protect your eyes and body. Use the correct welding screen and filter lens and wear protective

clothing.

S Protect bystanders with suitable screens or curtains.

FIRE HAZARD

S Sparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.

NOISE -- Excessive noise can damage hearing

S Protect your ears. Use earmuffs or other hearing protection.
S Warn bystanders of the risk.

MALFUNCTION -- Call for expert assistance in the event of malfunction.

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

PROTECT YOURSELF AND OTHERS!

SafE

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GB

2 INTRODUCTION

2.1 General

Tramtrac II is a welding carriage designed for surfacing of embedded tram rails. It is
provided with a built-- in wire feed unit, a welding gun and a holder for the wire reel.
The welding carriage only needs to be completed by a welding power source.

The welding gun mount can be adjusted for horizontal or vertical welding, forehand
or backhand. A meniscal sledge allows the gun angle to be adjusted stepplessly
without changing the position of the wire in the joint.

To ensure stable advancement 2 electric motors drive each one wheel set. The
wheels are spiny in order to guarantee good friction against the rail. The carriage is
controlled by two spring--loaded wheels at the bottom of the rail.

The connection to the power source is done by way of a prepared control cable at
the wire feed terminal, where the power supply and the start/stop functions are
included, and a welding cable for the welding current.

The control of Tramtrac II is done from a built--in control panel, from where welding
direction, travel speed , wire feed speed, welding on/off, high--speed transport,
inching and reversing of the wire are controlled.

1. Wire feed

2. Wir reel

3. Weight

4. Guide wheel

5. Drive wheels (4 pcs.)

6. Welding gun

7. Adjusting the gun angle

8. Horizontal slide

9. Vertical slide

10. Wire conduit

1 1. Control panel

12. Lifting handle

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GB

2.2 Technical data

Tramtrac II

Supply voltage 36 -- 46 VAC
Power 90 W
Welding speed 30 -- 1100 mm/min
Dimensions ( l x w x h ) 600x300x150 mm
Weight (without wire reel) 12 kg
Track gauge, carriage 100mm
Max. difference in altitude, bottom rail 10mm
Wire feed speed 6--12 m/min
Wire diameter Ø1,2--1,6 mm
Max. current, start relay 2A
Connection Burndy, 12 stift
Enclosure class IP 23

Enclosure class

The IP code indicates the enclosure class, i. e. the degree of protection against penetration by solid
objects or water. Equipment marked IP 23 is designed for indoor and outdoor use.

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GB

3 INSTALLATION

3.1 General

The installation must be executed by a professional.

For the connection of Tramtrac II to an ESAB welding power source, see control
cables under Accessories on page 11.

Tramtrac II can also be powered by other welding power sources via a separate
transformer, see page 9.

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GB

Tramtrac II to other makes of welding power sources

When connecting Tramtrac II to other welding power sources, use the transformer
and the control cable you find under Accessories on page 11.

F – G = Start / Stop function

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GB

4 OPERATION

4.1 General

General safety regulations for the handling of the equipment can be found on
page 4. Read through before you start using the equipment!

S Wipe the bottom of the rail clean in the area to be welded.
S Place Tramtrac II on the rail.
S Make sure that both guide wheels bear on the bottom of the rail.
S Connect the control and welding current cables to Tramtrac II and the welding

power source.

S Adjust the position of the welding gun. As a test, run Tramtrac II a short distance

without welding.

4.2 Handling

1. Travel direction, Left (without welding)

2. Travel direction, Right (without welding)

3. High--speed transport (On / Off)

4. Travel speed (carriage)

5. Wire feed speed (Welding current)

6. Reversing the wire

7. Manual wire feed

8. Start / Stop (Left/ Right with welding)

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GB

5 MAINTENANCE

5.1 General

Note:

All warranty undertakings given by the supplier cease to apply if the customer
attempts to rectify any faults on the machine during the warranty period.

5.2 Daily

S Check that cables and connections are intact.
S Clean the guide wheels and lubricate the hub using thin oil.

5.3 As necessary

S Replace the wire conduit and the contact tip.
S Replace the spatter protection and the guide wheels.

6 ACCESSORIES

Control cable 10 m 0457 360 884...................

Transformer 0457 467 880.........................

Weldingcable10m,50mm

2

0152 349 908..........

7 ORDERING OF SP ARE PARTS

Tramtract II is designed and tested in accordance with the international and European
standards IEC/EN 60204--1, ISO/EN 12100--2 and IEC/EN 60974--10 .
It is the obligation of the service unit which has carried out the service or repair work
to make sure that the product still conforms to the said standard.

Spare parts are ordered through your nearest ESAB representative, see back cover.
When ordering spare parts, please state machine type and number as well as desig­nation and spare part number as shown in the spare parts list on page 15.
This will simplify dispatch and ensure you get the right part.

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Dimension drawing

fhc3dim

-- 1 2 --

Diagram

PR1

1

3

SPEED

2

R1

M

A

B

XS3

XP3

A

B

Wire Speed

PR2

X1_3

X3_3

3

1

X1_1

2

X1_2

K1_1

K2_1

R2

SW5

X2_4

K1_2

2

SW2_A

1 3 5

2

Wire rev.

X1_4

K1

SW1_A

1 3

SW3_A

1

rev

31

2

2

Wire feed

X3_4

K2_2

3

SW4

K2

SW3_B

4 6

2

feed

31

5

Start Welding

K1

K1_2

SW1_B

4 6

X1_4

5

Direction

K2

X3_4

K1_2

X2_4

K1_1

K2_1

4 6

X1_1

SW2_B

X1_2

X1_3

X3_3

XS2

A

B

A

B

XP2

M

X2_1

X2_2

XP1

Connectors PC board

X2 X3 X1

4

3

2

1

WIRE FEED

unit

42V

BA

4

3

2

1

F2

X3_1

F

X3_2

F2

CARRIAGE

F1F1

unit

X3_1

X3_2

4

3

2

1

X2_1

X2_2

fhc3diag

-- 1 3 --

sida

-- 1 4 --

Spare parts list

Edition 2008--04--24

spare

-- 1 5 --

Spare parts Carriage

Item

Qty Ordering no. Denomination Notes

no.

1 0814 721 600 Wire feed complete See on page 20.
2 0814 721 700 Electronics complete See on page 21.
3 0814 721 610 Wire conduit
4 0398 145 210 Slide
5 0398 145 105 Vertical rod
6 0398 145 808 Intermediate bracket
8 0814 721 501 Drive wheel module front complete See on page 18.

9 0814 721 210 Counterweight
10 0814 721 301 Chassis base, compl. with steering wheel See on page 17.
11 0814 721 100 Cover compl. with clamps See on page 17.
12 0814 721 502 Drive wheel module rear complete See on page 18.
13 0814 721 401 Welding gun bracket complete with angular

slide

See on page 19.

2

3

1

4

5

6

tramtracspare

8 9 10 11 12

-- 1 6 --

4

13

Spare parts Chassis

Item

Qty Ordering no. Denomination Notes

no.

1-- 3 0814 721 100 Cover compl. with clamps

1 0814 721 201 Clamp

2 0814 721 101 Aluminium cover

3 08147 21 102 Top cover

4 0146 967 881 Brake hub

5 0814 721 311 Guide wheel

6 0814 721 312 Steering wheel spring

7 0814 721 310 Guide wheel bracket

8 0814 721 320 Bottom chassis

1

2

3

4

5

6

7

8

7

6

tramtracspare

5

-- 1 7 --

Spare parts drive wheel modules

Item

Qty Ordering no. Denomination Notes

no.

1 0814 721 522 Drive wheel modules, front motor

2 0814 721 521 Drive wheel modules, rear motor

3 0814 721 510 Motor with gear

4 0814 721 520 Motor cover

5 0814 721 511 Bevel gear drive

6 0814 721 531 External wheel nut

7 0814 721 530 Drive wheel

8 0814 721 532 Internal wheel nut

9 0814 721 512 Swing plate
10 0814 721 551 Stretch balancer
11 0814 721 561 Motorcablewithplug

2

1

3

3

10

4

11

5

4

5

tramtracspare

-- 1 8 --

8

76789

Spare parts Angular slide

Item

Qty Ordering no. Denomination Notes

no.

1--7 0814 721 401 Welding gun bracket, complete with angular slide

1 0814 721 411 Shaft with cog wheel

2 0814 721 412 Angular slide bracket

3 0814 721 414 Angular slide chain

4 0814 721 413 Angular slide

5 0417 855 001 Aluminium hand wheel M8

6 0814 721 415 Rod gun bracket

7 0814 721 416 Support, contact tube

8 0814 721 620 Contact tube

1

5

2

6

3

7

4

8

tramtracspare

-- 1 9 --

Spare parts Wire feed

Item

Qty Ordering no. Denomination Notes

no.

1-- 11 0814 721 600 Wire feed complete

1 0449 903 005 Motor cover

2 0449 903 410 Motor and gear, wire feed unit

3 0449 903 009 Wire conduit

4 0449 903 011 Wire feed housing

5 0449 903 027 Pressure spring

6 0449 903 028 Pressure screw

7 0449 903 029 Tightening screw with lock nut

8 0449 903 015 Cover

9 0449 903 014 Feed wheel

10 0449 903 012 Fork with pressure wheel

11 0449 903 013 Hub for feed wheel

12 3 4567

tramtracspare

891011

-- 2 0 --

Spare parts Control unit

Item

Qty Ordering no. Denomination Notes

no.

0814 721 700 Electronics complete

1 0814 721 711 Switch high speed

2 0449 902 431 Push--button “speed”

3 0814 721 713 Push--button wire feed speed

4 0457 357 401 Switch

5 0814 721 715 Rotary switch, start/stop

6 0814 721 716 Chassis plug female with cable 8pin

7 0814 721 717 Chassis plug male with cable 12 pin

8 0417 855 007 Chassis plug, male 2pin

1

50

70

30

cm/min

5

0

1

4

90

0

150

110

2

130

3

9

8

7

m/min

6

12

10

11

4

tramtracspare

6786

-- 2 1 --

ESAB subsidiaries and representative offices

Europe

AUSTRIA

ESAB Ges.m.b.H
Vienna--Liesing
Tel: [phone]
Fax: [phone]

BELGIUM

S.A. ESAB N.V.
Brussels
Tel: [phone]
Fax: [phone]

THE CZECH REPUBLIC

ESAB VAMBERK s.r.o.
Vamberk
Tel: [phone]
Fax: [phone]

DENMARK

Aktieselskabet ESAB
Herlev
Tel:[phone]
Fax:[phone]

FINLAND

ESAB Oy
Helsinki
Tel: [phone]
Fax: [phone]

FRANCE

ESAB France S.A.
Cergy Pontoise
Tel:[phone]
Fax:[phone]

GERMANY

ESAB GmbH
Solingen
Tel: [phone]
Fax: [phone]

GREAT BRITAIN

ESAB Group (UK) Ltd
Waltham Cross
Tel: [phone]
Fax: [phone]

ESAB Automation Ltd
Andover
Tel: [phone]
Fax: [phone]

HUNGARY

ESAB Kft
Budapest
Tel:[phone]
Fax:[phone]

ITALY

ESAB Saldatura S.p.A.
Mesero (Mi)
Tel:[phone]
Fax:[phone]

THE NETHERLANDS

ESAB Nederland B.V.
Amersfoort
Tel: [phone]
Fax: [phone]

NORWAY

AS ESAB
Larvik
Tel:[phone]
Fax:[phone]

POLAND

ESAB Sp.zo.o.
Katowice
Tel: [phone]
Fax: [phone]

PORTUGAL

ESAB Lda
Lisbon
Tel: [phone]
Fax: [phone]

SLOVAKIA

ESAB Slovakia s.r.o.
Bratislava
Tel:[phone]
Fax:[phone]

SPAIN

ESAB Ibérica S.A.
Alcalá de Henares (MADRID)
Tel: [phone]
Fax: [phone]

SWEDEN

ESAB Sverige AB
Gothenburg
Tel:[phone]
Fax:[phone]

ESAB international AB
Gothenburg
Tel:[phone]
Fax:[phone]

SWITZERLAND

ESAB AG
Dietikon
Tel: [phone]
Fax: [phone]

North and South America

ARGENTINA

CONARCO
Buenos Aires
Tel: [phone]
Fax: [phone]

BRAZIL

ESAB S.A.
Contagem--MG
Tel: [phone]
Fax: [phone]

CANADA

ESAB Group Canada Inc.
Missisauga, Ontario
Tel: [phone]
Fax: [phone]

MEXICO

ESAB Mexico S.A.
Monterrey
Tel: [phone]
Fax: [phone]

USA

ESAB Welding & Cutting Products
Florence, SC
Tel: [phone]
Fax: [phone]

Asia/Pacific

CHINA

Shanghai ESAB A/P
Shanghai
Tel: [phone]
Fax: [phone]

INDIA

ESAB India Ltd
Calcutta
Tel: [phone]
Fax: [phone]

INDONESIA

P.T. ESABindo Pratama
Jakarta
Tel: [phone]
Fax: [phone]

JAPAN

ESAB Japan
Tokyo
Tel: [phone]
Fax:[phone]

MALAYSIA

ESAB (Malaysia) Snd Bhd
Selangor
Tel: [phone]
Fax:[phone]

SINGAPORE

ESAB Asia/Pacific Pte Ltd
Singapore
Tel:[phone]
Fax: [phone]

SOUTH KOREA

ESAB SeAH Corporation
Kyungnam
Tel: [phone]
Fax: [phone]

UNITED ARAB EMIRATES

ESAB Middle East FZE
Dubai
Tel: [phone]
Fax: [phone]

Representative offices

BULGARIA

ESAB Representative Office
Sofia
Tel/Fax: [phone]

EGYPT

ESAB Egypt
Dokki--Cairo
Tel: [phone]
Fax: [phone]

ROMANIA

ESAB Representative Office
Bucharest
Tel/Fax: [phone]

RUSSIA

LLC ESAB
Moscow
Tel: [phone]
Fax: [phone]

LLC ESAB
St Petersburg
Tel: [phone]
Fax: [phone]

Distributors

For addresses and phone
numbers to our distributors in
other countries, please visit our
home page

www.esab.com

ESAB AB
SE--695 81 LAXÅ
SWEDEN
Phone [phone]

www.esab.com

070514