ESAB Tramtrac II is a welding carriage for surfacing embedded tram rails. It features a built-in wire feed, welding gun, and wire reel holder, requiring only a welding power source to complete the setup. The carriage's mount adjusts for horizontal or vertical welding, allowing for forehand or backhand techniques. It also includes a meniscal sledge for adjusting the gun angle. Two electric motors with spiny wheels drive the carriage, ensuring stable advancement and friction against the rail.
ESAB Tramtrac II is a welding carriage for surfacing embedded tram rails. It features a built-in wire feed, welding gun, and wire reel holder, requiring only a welding power source to complete the setup. The carriage's mount adjusts for horizontal or vertical welding, allowing for forehand or backhand techniques. It also includes a meniscal sledge for adjusting the gun angle. Two electric motors with spiny wheels drive the carriage, ensuring stable advancement and friction against the rail.
GB
Valid for serial no. 06470460 231 001 GB 2008--04--24
Tramtrac
t
II
Instruction manual
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DECLARATION OF CONFORMITY
ESAB AB, Welding Equipment, SE--695 81 Laxå, Sweden, gives its unreserved guarantee that
automatic welding machine Tramtrac
t
II 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).
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Kent Eimbrodt
Global Director
ESAB AB, Welding Equipment
SE--695 81 LAXÅ
SWEDEN Tel: + 46 584 81000 Fax: + 46 584 411721
L
axå 2006--12--21
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TOCe
Rights reserved to alter specifications without notice.
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 SPARE PARTS 11......................................
DIMENSION DRAWING 12................................................
DIAGRAM 13............................................................
SPARE PARTS LIST 15...................................................
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SafE
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 recommen-
dations 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.
GB
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SafE
WARNING
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.
ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE PRECAU-
TIONS 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 s tandards.
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 y our 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 y our ears. Use earmuffs or other hearing protection.
S Warn bystanders of the risk.
MALFUNCTION -- Call for expert assistance in the event of malfunction.
PROTECT YOURSELF AND OTHERS!
GB
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fhc3d1ea
2 INTRODUCTION
2.1 General
Tr amtrac 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. T he 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
11. Control panel
12. Lifting handle
GB
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fhc3d1ea
2.2 Technical data
T ramtrac 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
T rack 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.
GB
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fhc3i1ea
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.
GB
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fhc3i1ea
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
GB
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fhc3o1ea
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. Tr avel direction, Left (without welding)
2. Tr avel direction, Right (without welding)
3. High--speed transport (On / Off)
4. Tr avel speed (carriage)
5. Wire feed speed (Welding current)
6. Reversing the wire
7. Manual wire feed
8. Start / Stop (Left/ Right with welding)
GB
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fhc3a1ea
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...................
Tr ansformer 0457 467 880.........................
Weldingcable10m,50mm
2
0152 349 908..........
7 ORDERING OF SPARE PARTS
T ramtract 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 desig-
nation 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.
GB
Dimension drawing
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fhc3dim
Diagram
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fhc3diag
SW1_A
2
1 3
5
4 6
2
1 3 5
4 6
2
1
3
SW1_B
SW2_A
SW2_B
SW3_A
Start Welding
R1
1
3
2
PR1
Direction
5
4 6
SW3_B
Wire feed
Wire rev.
K2
SW5
2
31
Wire Speed
X1_2
SPEED
X2_1
X2_2
F
X3_1
42V
A
B
X1_3
X3_3
XP3
XP1
rev
X1_1
F2
R2
K2_2
K1_2
F2
X3_2
K2
K1_2
K1
BA
M
A
B
XS3
K1
3
1
2
PR2
X1_2
X1_1
X3_1
X3_2
SW4
2
31
feed
X1_4
X3_4
X2_4
X2_1
X2_2
F1F1
K1_2
X2_4
X1_4
X3_4
A
B
X1_3
X3_3
XP2
M
A
B
XS2
WIRE FEED
unit
CARRIAGE
unit
K1_1
K2_1
K1_1
K2_1
Connectors PC board
X2 X3 X1
1
2
3
4
1
2
3
4
1
2
3
4
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sida
Spare parts list
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spare
Edition 2008--04--24
-- 1 6 --
tramtracspare
Spare parts Carriage
Item
no.
Qty Ordering no. Denomination Notes
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.
3
4
5
6
2
1
4
8 9 10 11 12
13
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tramtracspare
Spare parts Chassis
Item
no.
Qty Ordering no. Denomination Notes
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
5
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tramtracspare
Spare parts drive wheel modules
Item
no.
Qty Ordering no. Denomination Notes
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
8
5
11
10
3
2
76789
1
3
4
5
4
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tramtracspare
Spare parts Angular slide
Item
no.
Qty Ordering no. Denomination Notes
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
2
3
4
5
6
7
8
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tramtracspare
Spare parts Wire feed
Item
no.
Qty Ordering no. Denomination Notes
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
891011
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ESAB Tramtrac II is a welding carriage for surfacing embedded tram rails. It features a built-in wire feed, welding gun, and wire reel holder, requiring only a welding power source to complete the setup. The carriage's mount adjusts for horizontal or vertical welding, allowing for forehand or backhand techniques. It also includes a meniscal sledge for adjusting the gun angle. Two electric motors with spiny wheels drive the carriage, ensuring stable advancement and friction against the rail.
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