1. 03800B RAIL PREHEATER

2. General Safety Precautions
REMEMBER ALL PPE
TOOL OPERATORS AND MAINTENANCE PERSONNEL MUST ALWAYS COMPLY WITH THE SAFETY PRECAUTIONS GIVEN IN THE MANUAL, AND WITH ALL STICKERS AND TAGS ATTACHED TO THE TOOL AND HOSE. ALL SAFETY PRECAUTIONS ARE GIVEN FOR YOUR SAFETY. READ OPERATER MANUAL TO UNDERSTAND AND FOLLOW ALL SAFETY, MAINTENANCE AND OPERATION INSTRUCTIONS.
THE CUSTOMER MUST ASSUME RESPONSIBILITY FOR THE TOOL’S SUITABILITY FOR A PARTICULAR FUNCTION, FOR ANYONE USING THE TOOL OR MAINTAINING THE TOOL REGARDING THEIR FITNESS TO USE THE TOOL OR REPAIR THE TOOL, UNDERSTANDING OF THE OPERATION AND SAFETY AND MAINTENANCE MANUAL, INTELLIGENCE TO USE GOOD JUDGMENT NECESSARY TO WORK SAFELY AND EFFICIENTLY WITHOUT ENDANGERING THEMSELVES OR BYSTANDERS IN THE WORK AREA.

3. General Description 03800B Rail Pre-Heater DIMENSIONS L - 18” (457 mm)
W - 16” (406 mm)
H /2” (343mm)
WEIGHT
83 lbs.
(33 kg)
FLOW
10 gpm
(38 lpm)
Hydraulic PRESSURE
2000 PSI (140 BAR)
RPM
3400

4. General Description
03800B Rail Pre-Heater Torch / Inox Burner

5. NEVER USE OVER 50 FT. OF HOSE OR SPLICE HOSE LENGTHS TOGETHER!
General Description
Pre-Heater Torch Hoses (HPAP50)
AIR
PROPANE
AIR
- 3/4” Inside Diameter
50 ft. MAX LENGTH
PROPANE
3/8” Inside Diameter
- 50 ft. MAX LENGTH
NEVER USE OVER 50 FT. OF HOSE OR SPLICE HOSE LENGTHS TOGETHER!

6. General Description Rail Pre-Heater Settings AIR PROPANE
- 3-5 PSI PSI
TORCH HEIGHT
Even with mold
chamber
NEVER USE OVER 50 FT. OF HOSE OR SPLICE HOSE LENGTHS TOGETHER!

7. General Description Connections and Knobs / Valves
HYDRAULIC Control Valve Knob
Propane Regulator Valve &
Gages
HYDRAULIC Power Source
AIR Torch Hose &
Gage
Propane Tank
Flex-Hose
PROPANE
Torch Hose

8. Pre-Heater Setup Make sure the power source is turned off.
Make sure all knobs are turned to the “OFF” position on the Pre-Heater.
Connect all the hoses, ensuring a proper fit.
Loop the service hose in the work area in such a way to relieve stress on the hose and quick disconnect fittings while working. Be aware of hose location at all times.

9. Pre-Heater Setup
5. Turn the hydraulic power source to the “on” position to supply 10 gpm.
6. Start the pre-heater unit by turning hydraulic control valve to the “ON” position.
LET THE BLOWER RUN 2 OR 3 MINUTES TO ALLOW UNIT TO WARM UP, THEN TURN THE HYDRAULIC CONTROL VALVE TO THE “OFF” POSITION
TURN HYDRAULIC POWER SOURCE OFF AT THIS TIME.

10. Pre-Heater Setup
7. Connect the propane flex-hose from the regulator/propane tank to the pre-heater.
8. The inox heating nozzle must be aligned in the molds so that the flat piece just above the nozzle is no higher than the top of the inside of the mold (where the diverter plug fits in). The nozzle must be aligned in such a way that the tip of the nozzle is straight up and down perpendicular to the rail.

11. Position for lighting flame
Pre-Heater Setup
9. Prior to starting the rail pre-heater, the nozzle needs to be tilted all the way back so the nozzle is pointing to the side of the mold. This is necessary to help start the flame.
Original alignment
Position for lighting flame
The torch stand pivots up and down for this purpose.

12. HYDRAULIC Control Valve Knob Propane Regulator Valve
Pre-Heater Setup
10. Make sure the propane regulator valve (located on the Rail pre-heater) is turned all the way out (counterclockwise).
11. Turn the hydraulic power source to the “on” position to supply 10 gpm.
12. Turn hydraulic control valve knob clockwise, on the rail pre-heater, to activate the blower.
13. With the rail pre-heater unit
operating, open the shut off valve
on the propane tank all the way.
HYDRAULIC Control Valve Knob
Propane Regulator Valve

13. Propane Regulator Valve &
Pre-Heater Setup
14. With the propane shut-off valve located on the inox burner completely open, adjust the propane regulator to psi.
15. With the rail pre-heater unit operating, open the air bypass valve located at the inox burner to adjust air pressure for ease of lighting the burner. To light the inox burner open the propane shut off valve ½ to ¾ turn. The burner can be lit with a torch or a striker.
Propane shut-off valve
Propane Regulator Valve &
Gages
Air Bypass Valve

14. Pre-Heater Setup
Air Bypass Valve
Propane shut-off valve

15. Pre-Heater Setup
16. After lighting slowly close air by-pass valve. Let the flames warm the molds for seconds, slowly position the nozzle in the mold so it is straight up and down, perpendicular to the rail. Look at the flames in the mold, the flames should be down in the rail area not just in the risers. Flames should be 6 to 8 inches coming out of the risers. If the flames are only in the risers and not in the rail area, turn the nozzle to the side and slowly straighten again. It will be necessary to adjust the flame at the propane on-off valve to fine-tune the flame. You should not hear a lot of popping or spitting, rather you should hear a sound similar to that of a turbine or jet engine.

16. Pre-Heater Setup
17. Once the flame is fine tuned, start the preheat time.
During pre-heat the flame will burn more efficiently. More propane can be added just to flutter and backed off to sound like turbine.
A.) PREHEAT ALL 5-1/2” BASE RAIL FOR 5-6 MINUTES.
B.) PREHEAT ALL 6” BASE RAIL FOR 6-7 MINUTES.
C.) PREHEAT ALL W.G.W. WELDS FOR 6-1/2 MINUTES.
DO NOT HEAT RAIL ENDS MORE THAN 8 MINUTES.
AT THE END OF PREHEAT THE TOP OF THE BASE OF THE RAIL SHOULD BE 450 DEGREES F MINIMUM AT 2-1/2 INCHES FROM THE RAIL ENDS, TESTED WITH A TEMPSTICK.
18. After preheating the rail remove the inox nozzle from the mold. Next,
completely close propane on-off valve. Before shutting rail pre-heater
unit down.
Note: should operating experience prove that blower capacity is too
high for the actual air requirements, any excess may be blown off
continuously through the manual unloading valve located on the
inox burner.

17. If working with a weak Hydraulic system,
it may be necessary to adjust the flow to
reach desired RPM

20. CLIP- Adjusting the torch (1” Weld)

21. CLIP- Lighting the Torch (1” Weld)

22. CLIP- Preheat / Flame (1” Weld)

23. QUESTIONS?