Servo Controlled FBW With Power Boost Control, Operations & Maint. Manual

Holland L.
P
www.hollandco.com
SERVO CONTROLLED FLASH BUTT WELDING

MACHINE
WITH POWER BOOST CONTROLS
OPERATION AND MAINTENANCE MANUAL
MODEL: H-1000
SN: WH-8-0300
ASIAKOM, MALAYSIA
Holland L.P.
1000 Holland Drive
Crete, Illinois 60417-2120
Phone: (708) 672-2300
FAX: (708)-672-0119
Web Site: www.hollandco.com
Holland Equipment Division's Quality Management

System is ISO 9001:2015
H-1000 Welding Machine with Power Boost Controls
Operation & Maintenance Manual
www.hollandco.com
NOTES
File Name Rev. Released by Release Date Page #

H1000 Operation &
0 K.A.Costabile April 3, 2019 Page 2 of 125
Maintenance Manual
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INTRODUCTION
STATEMENT OF CONFIDENTIALITY
All information contained in this manual is to be considered confidential and proprietary to Holland, L.P. of Crete
Illinois. This includes but is not limited to any electronic document versions or copies of this manual provided to
the customer by Holland, L.P. in any form or format.
No portion of this manual or constituent item in whole or in part, shall be copied, scanned, faxed, transmitted
electronically, extracted, de-compiled, or otherwise duplicated to be shared sold or given to any other agency
without the express written consent of Holland, L.P.
Holland, L.P.
1000 Holland Drive
Crete, IL 60417-2120 USA
DISCLAIMER
This machine is designed, manufactured and sold for the purpose of flash butt welding of railroad rail. Any use by
the user for any other purpose is expressly forbidden and will relieve Holland L.P. of any liability for breach of
warranty or the breach of any other contractual obligation
The user (unless expressly permitted by Holland L.P in writing) will not:
• Change the form, design or arrangement of the machine
• Modify the componentry
• Use the machine or components from their designated purpose
• Add components not approved by the manufacturer.
Any such modifications or changes will relieve Holland L.P. of any responsibility for performance of the product,
quality of its production, or reliability related to the safety of personnel operating the vehicle.
ISO COMPLIANCE
Holland Equipment Division’s Quality Assurance System is ISO 9001:2015.
DRAWINGS AND ILLUSTRATIONS
Drawings and Illustrations are the property of Holland L.P. who claims proprietary rights in the material disclosed.
It is issued in confidence for engineering information only and may not be copied or used to manufacture of
anything shown without the specific written permission from Holland L.P. Holland L.P. reserves the right to modify
details not affecting the strength or application as may be necessary to facilitate manufacture and improve design.

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Maintenance Manual
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NOTES

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Table of Content
SECTION 1 ............................................................................................................................................................................ 7
INTRODUCTION ....................................................................................................................................................................... 7
DISCLAIMER ........................................................................................................................................................................ 9
EQUIPMENT WARRANTY POLICY ...................................................................................................................................... 10
SECTION 2 .......................................................................................................................................................................... 11
SAFETY ................................................................................................................................................................................... 11
SAFETY-GENERAL.............................................................................................................................................................. 13
Safety (Continued) General .............................................................................................................................................................. 14
Safety (Continued) Hydraulic System Safety ................................................................................................................................... 15
Safety (Continued) Clean Grease From Fittings Following Lube ........................................................................................................ 16
SAFETY RULES .................................................................................................................................................................... 17
SECTION 3 .......................................................................................................................................................................... 19
SYMBOLS ............................................................................................................................................................................... 19
SYMBOLS USED IN THIS MANUAL ...................................................................................................................................... 21
SECTION 4 .......................................................................................................................................................................... 27
PRODUCTDESCRIPTION ......................................................................................................................................................... 27
TECHNICAL DATA .............................................................................................................................................................. 29
WELDING MACHINE .......................................................................................................................................................... 30
General Description ......................................................................................................................................................................... 30
H1000 GENERAL ARRANGEMENT ...................................................................................................................................... 31
Welder Head Front View ................................................................................................................................................................ 31
Welder Head Right End View .......................................................................................................................................................... 32
Welder Head - Rear View ................................................................................................................................................................ 33
Welder Head Left End View ............................................................................................................................................................ 34
Welder Head Suspension Components .......................................................................................................................................... 35
INTERNAL SHEAR DIE MECHANISM, GENERAL ARRANGEMENT ...................................................................................... 36
WELDERHEAD LUBE DIAGRAM......................................................................................................................................... 37
WELDER HEAD LUBE POINTS (DETAIL) .............................................................................................................................. 38
WELDER HEAD LUBE POINTS (DETAIL) CONTINUED .......................................................................................................... 39
WELDER HEAD LUBE POINTS (DETAIL) CONTINUED ......................................................................................................... 40
ELECTRICAL SYSTEM GENERAL DESCRIPTION ..................................................................................................................... 41
HYDRAULIC SYSTEM .......................................................................................................................................................... 42
WELDER CONTROL PANEL.................................................................................................................................................. 44
EMERGENCY STOP BUTTON (RED) .................................................................................................................................................. 45
SHEARING SELECTOR-SWITCH ........................................................................................................................................................ 45
WELD CYCLE RUN-GREEN LIGHT ..................................................................................................................................................... 46
WELD CYCLE STOP-PUSH BUTTON .................................................................................................................................................. 46
WELD CYCLES START-PUSH BUTTON .............................................................................................................................................. 46
PLATEN-SELECTOR SWITCH............................................................................................................................................................. 47
INDICATING LIGHTS (AMBER): PLATEN FORWARD, REVERSE, AND HIGH SPED SELECTOR SWITCH .............................................. 47
RAIL CLAMPS-SELECTOR SWITCH .................................................................................................................................................... 48
CLAMP RELEASE – SELECTOR SWITCH ............................................................................................................................................ 49
OPERATING MODE-SELECTOR SWITCH ........................................................................................................................................... 50
HYDRAULIC PRESSURE-SELECTOR SWITCH ..................................................................................................................................... 51
OPERATING MODE AND HYDRAULIC MODE COMBINATION .......................................................................................................... 52
OPERATING MODE AND HYDRAULIC MODE COMBINATION .......................................................................................................... 53

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SECTION 5 .......................................................................................................................................................................... 55
PRODUCTOPERATION............................................................................................................................................................ 55
WELDER PREPARATION ..................................................................................................................................................... 57
WELDING PROCESS ........................................................................................................................................................... 59
General Description......................................................................................................................................................................... 59
CLAMP ANGLE CHECK PROCEDURE .................................................................................................................................. 60
Overview ......................................................................................................................................................................................... 60
Clamping Forces .............................................................................................................................................................................. 61
Clamping Angle ............................................................................................................................................................................... 61
SYSTEM PRE-CHECK PROCEDURE ..................................................................................................................................... 62
Check System Pressure ................................................................................................................................................................... 62
Measure Clamp Angle ..................................................................................................................................................................... 63
RAIL PREPARATION........................................................................................................................................................... 67
WELDING SEQUENCE ........................................................................................................................................................ 70
THE WELDING SEQUENCE-DETAILED................................................................................................................................ 71
SETUP AND WELD ............................................................................................................................................................. 72
SECTION 6 .......................................................................................................................................................................... 83
PRODUCTMAINTENANCE ...................................................................................................................................................... 83
MAINTENANCE INSTRUCTION-GENERAL .......................................................................................................................... 85
MAINTENANCE ................................................................................................................................................................. 87
Shift Maintenance ........................................................................................................................................................................... 88
Daily Maintenance .......................................................................................................................................................................... 92
Weekly Maintenance ...................................................................................................................................................................... 97
Monthly Maintenance ................................................................................................................................................................... 102
Quarterly Maintenance................................................................................................................................................................. 103
Semi-Annual Maintenance ............................................................................................................................................................ 104
Annual Maintenance ..................................................................................................................................................................... 107
18-Month Maintenance ................................................................................................................................................................ 108
2 Years / Bi-Monthly ..................................................................................................................................................................... 110
5 Years .......................................................................................................................................................................................... 111
Replace As Required ..................................................................................................................................................................... 112
CHECK LISTS...................................................................................................................................................................... 115
System Pre Start -Up Check List ....................................................................................................................................................... 115
System Post Start Check List ......................................................................................................................................................... 116
Shut Down ..................................................................................................................................................................................... 117
SECTION 7 ........................................................................................................................................................................ 119

TROUBLESHOOTING ............................................................................................................................................................ 119
TROUBLESHOOTING GUIDE FOR WELDER AND CONTROLS ........................................................................................... 121
PARTS ORDERING INFORMATION SHEET ....................................................................................................................... 125

H1000 Operation &
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SECTION 1
INTRODUCTION

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Maintenance Manual
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NOTES

H1000 Operation &
Maintenance Manual
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DISCLAIMER
This machine is designed and manufactured for the purpose of flash butt welding of railroad rail. Any
use by the user for any other purpose is expressly forbidden and will relieve Holland L.P. of any liability
for breach of warranty or the breach of any other contractual obligation pertaining to warranty or operation
and product quality.
The user (unless expressly permitted by Holland L.P. in writing) will not:
• Change the form, design or arrangement of the machine.
• Modify the componentry.
• Repurpose the machine or components from their designed purpose.
• Add components not approved by the manufacturer
Any such modifications or changes will relieve Holland L.P. of any responsibility for performance of the
product, quality of its production, or liability related to the safety of personnel operating the machine.
STATEMENT OF CONFIDENTIALITY
All information contained in this manual is to be considered confidential and proprietary to Holland, L.P.
of Crete Illinois. This includes but is not limited to any electronic document versions or copies of this
manual provided to the customer by Holland, L.P. in any form or format.
Holland, L.P.
1000 Holland Drive Crete, IL, 60417-2120 USA
No portion of this manual or constituent item in whole or in part, shall be copied, scanned, faxed,
transmitted electronically, extracted, de-compiled, or otherwise duplicated to be shared sold or given to
any other agency without the express written consent of Holland, L.P.
ISO COMPLIANCE
Holland Equipment Division’s Quality Assurance System is ISO 9000:2001 Registered with QMI in 2001.
DRAWINGS AND ILLUSTRATIONS
Drawings and Illustrations are the property of Holland L.P. who claims proprietary rights in the material
disclosed. It is issued in confidence for engineering information only and may not be copied or used tor
manufacture of anything shown without the specific written permission from Holland L.P. Holland L.P.
reserves the right to modify details not affecting the strength or application as may be necessary to
facilitate manufacture and improve design.

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Maintenance Manual
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EQUIPMENT WARRANTY POLICY
1. HOLLAND warrants that the equipment or any other goods supplied under this order will be free from defects in material
and workmanship and will be of the kind and quality designated in the Contract.
2. HOLLAND warranty period begins upon the completion of the commissioning of the equipment and will be in effect for a
period of 12 months or 15,000 welds, whichever occurs first.
3. Normal wear and tear is specifically excluded from this warranty.
4. If it appears, within the specified warranty period, that the equipment or any other goods supplied under this order do not
meet the warranties specified above, HOLLAND agrees to correct any defect, at its option, either by repairing any
defective parts or by making available F.O.B. Crete, Illinois, repaired or replacement parts, provided the BUYER notifies
HOLLAND promptly of any such defects, submits the necessary evidence by returning at its expense (including freight,
customs and taxes) the defective parts to HOLLAND’s plant in Crete, Illinois, for HOLLAND’s evaluation, and provided
further that during said warranty period the equipment or other goods have been properly cared for, operated under
normal conditions, and with competent supervision.
5. HOLLAND will not assume any expense or liability for repairs made outside its plant or repair shop without HOLLAND’s
prior written consent.
6. The liability of HOLLAND to the BUYER arising out of the use of, or the supplying of, said equipment or other goods under
this order, whether under theories of warranty, contract or otherwise, is limited to the amount of the purchase price of
said equipment or other goods.
7. Equipment or other goods, which are not manufactured by HOLLAND, are not warranted except insofar as, and to the
extent that, the same are warranted to HOLLAND by the manufacturer.
8. There is no charge for labor during the warranty period; however, the BUYER must pay all warranty- related travel
expenses incurred by HOLLAND service personnel.
9. Repair or replacement as provided under this warranty is the exclusive remedy of BUYER. HOLLAND shall not be liable for
any incidental or consequential damages or any lost profits for breach of any express or implied warranty on equipment
or other goods under this order. Except to the extent prohibited by applicable law, This warranty is Exclusive and in lieu
of all other warranties, express or implied, including but not limited to any implied warranty of merchantability or of fitness
for a particular purpose.
10. The validity of this warranty is subject to the following conditions:

A. The equipment must be operated by HOLLAND trained and certified operators; such certification shall be
given during the training and commissioning of the equipment.
B. The prescribed preventive maintenance program must be adhered to, with appropriate logs being
maintained as evidence that program is being followed.
C. Only HOLLAND parts or HOLLAND-approved parts shall be used in the operation and maintenance of the
equipment.
D. Payment of HOLLAND invoices must be current. Any invoices that remain unpaid after 60 days from the
date of invoice will not be considered current for purposes of this warranty.
If BUYER violates any of the above conditions, this warranty will automatically be considered null and void. Any parts or service
that are provided by HOLLAND beyond the term of this warranty, or if this warranty has been deemed null and void as a result
of a violation of the above conditions, will become immediately billable to BUYER.

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SECTION 2
SAFETY

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NOTES

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Maintenance Manual
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SAFETY-GENERAL
IMPORTANT NOTE:
The safety rules and requirements of the
owner or customer and the laws of the
country or state in which the unit
operates take precedence over material LOCK OUT and TAG OUT the Equipment –
on this page. Then TRY To Ensure NO FUNCTION

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Safety (Continued) General
PERSONAL INJURY
HAZARD
EQUIPMENT DAMAGE
HAZARD
NEVER for any reason
attempt to over-ride, disable
or alter any safety or
protective feature in any QUICK DISCONNECT FITTING CARE
system, whether electrical
or mechanical.
NO LEAKS
Doing so may cause serious
injury or death to personnel Do not repair this
and serious or even machine unless
technically
catastrophic damage to the qualified
unit.
No unauthorized
person may repair
this machine
WARNING
• Never operate welder with damaged or leaking quick
disconnects.
• Leaking fluid is a safety hazard and may cause fires if hot fluid
comes into contact with an ignition source.
• On track structures it may cause slips & falls.
• Leaks may also cause severe burns if hot fluid comes into
contact with skin.
• Hydraulic fluid is a pollutant. Leaks and spills may contaminate
the environment.

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Safety (Continued) Hydraulic System Safety

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Safety (Continued) Clean Grease From Fittings Following Lube

H1000 Operation &
Maintenance Manual
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SAFETY RULES
STAY ALERT
CAUTION
VOLTAGES EMPLOYED IN THIS PROCESS ARE SUFFICIENTLY HIGH TO CAUSE DEATH.
USE CAUTION AT ALL TIMES WHEN WORKING WITH THIS MACHINE
Handle machine with built in handles only, do not pull on power or hydraulic lines.
Heavy duty gloves must be worn at all times when working with the machine.
Eye protection must be worn at all times when working with the machine.
Main power must be switched off and locked out during maintenance work
When performing maintenance work the machine must be supported by a certified welder stand or on
the ground with gluts.
Transformer resistance must be systematically checked on a monthly basis (required resistance 1.0
mega ohms).
Care must be taken to ensure the grounding cable between the welder and truck frame is in place at
all times.
Operators must be familiar with electrical safety rules before working with the machine.
The machine must be kept dry at all times - do not pressure wash. All cleaning should be dry brush
methods or air blast.
Use extreme caution when handling electrodes. These items may be hot and could cause severe
burns.
Use extreme caution when removing cooling hoses, coolant temperature may be high enough to
scald.
Remove all flammable materials from the work zone.
Fire extinguishers must be located within easy access during operations.
Do not open welder covers during welding process.
Do not stand on wet ties when operating welding machine.
Keep machine clean at all times.
Remove weld splatter after each operation.

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Ensure that fire extinguishers are placed within easy access during all welding operations. Ensure that
all extinguishers are full, properly charged and in operational condition before welding starts. Replace all
discharged extinguishers immediately. Ensure that operators and helpers are trained in proper and
effective use of extinguishers.
Do not operate welder with covers moved aside or absent. Replace damaged covers immediately.
Do not stand on wet surfaces when operating the welding machine. Keep the welding machine clean at
all times.
Remove weld spatter after each operation.
DO NOT CHANGE MACHINE SETTINGS WITHOUT QUALIFIED STAFF INSTRUCTION

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Section 3
SYMBOLS

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Maintenance Manual
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NOTES

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SYMBOLS USED IN THIS MANUAL
Note: Not all the symbols on the following pages may be used in this manual. However, others may be
used multiple times and with variations as required.
Symbols
Description Symbol Description Symbol
Not OK
Do not do this. Do not use damaged
Forbidden filter
Refer to manual or Pollutant,

manufacturer’s environmental hazard
instructions potential
STOP,
Do Not Proceed,
Halt Fire Hazard
NO,
STOP,
Do Not Proceed, Inhalation Hazard
Halt
OK
YES, Emergency Stop
This way Location
Warning Hot (Generic)

Lockout Point
Slippery Surface,
Slipping Hazard
from Pinch Point
Spills

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Symbols
Struck By Caught Between
Injection Hazard
Guards From High
Pressure Fluids
Cutting or Tissue
Pinch Point
Caught in Moving
Disruption From
Parts High Pressure
Fluids.
Cut Hazard
Sharp Edges, Display Mode
Switch Display
Inhalation Hazard
Particulates (dust, High Voltage Hazard
mists)
Inhalation Hazard No Leaks

(Generic) No Spills
and/or
Entangled Irritant (skin, tissues,

Pulled In membranes)
No Smoking No Matches

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Symbols
Lock Out and Tag Out

Flying Debris
Sparks from
No Open Flames
welding
Burn Hazard Fire Hazard
Lockout and Tagout ZERO ENERGY

then Try STATE,
(No Stored, Residual
or Potential Energy in
the system)
Unlocked,
Not Secured Oil Fill
Locked,
Secured Grease Point
Warning:
Spray Lube Point
Hot Surface or item or
No Leaks Light Oil Lube Point
Clean with: Coolant Water Fill Point

Wire Brush

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Symbols
Clean with:
Air Blast
High Pressure Air Increase (Setting)
Clean with:
Power Wash
High Pressure Decrease (Setting)
Water Spray
Clean with:
Scraper or chisel Apply anti-spatter
(for weld spatter) compound (Protex or
equal)
Hand Auto, Automatic

(Selection, Setting) (Selection, Setting)
Rail Clamp, Clamp Rail Clamp, Unclamp

(Selection, Setting) (Selection, Setting)
Rail Clamp, Off Welding Flash (Eye

(Selection, Setting) Damage)
Shear Close (Selection,

Shear (Generic) Setting)
Shear Open
Platen, General
(Selection, Setting)

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Symbols
Platen Forward, Slow,

Platen Off, (Selection, (Selection, Setting)
Setting)
Platen Reverse, Slow

(Selection, Setting) Setup, High Speed,
(Selection, Setting)
Setup, (Selection, Weld Cycle Stop,

Setting) (Selection, Setting)
Weld Cycle Start,

(Selection, Setting) System Fault
or
Clamp Release, Right,

Run, (Selection, (Selection, Setting)
Setting)
Clamp Release, Left,

(Selection, Setting) Off, (Selection, Setting)
Recycle, Dispose of On, (Selection, Setting)

material properly

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NOTES

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Section 4
PRODUCT DESCRIPTION

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NOTES

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TECHNICAL DATA
Rated Voltage:
Mains ...............................................................................................................460 ±10%V
Hz ................................................................................................................................. 60
Electric Power Station ............................................................................................... 460V
Rated Primary Current (50% Duty Cycle) ........................................................... 540Amps
Rated Power (50% Duty Cycle) ........................................................................... 210KVA
Rated Working Pressure in the Hydraulic System ................................................. 22MPa
Rated Upset Force ..........................................................................1000KN (120000KGF)
Rated Clamping Force.....................................................................2900KN (290000KGF)
Mass ............................................................................................................................... 3100KG
Overall Dimensions (W × H × L) ........................................ 1000 mm × 970 mm×1895 mm
Production Rate .................................................. 12 Welds Per Hour (continuous flashing)
.................................................................................. 18 Welds Per Hour (pulse process)

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WELDING MACHINE
General Description
Rail welding is carried out by utilizing the principle of flash resistance welding. The H-1000 machine can
weld rails with a cross section of 12,000mm2.
The welding head consists of five principal assemblies:
1. Body (four quadrants) c/w clamping and upset device

2. Welding transformers (2)
3. Welding electrodes (4)
4. Flash removal device (integrated)
5. Controls (Hydraulic Manifold and Operator Panel)
The two halves of the welding head pivot around a central shaft (sliding) assembly. One half of the head
carries the two welding transformers (one in each quadrant). The other half of the welding head carries
the two upset cylinders. Special conducting rods in the upset cylinders connect the two halves of the
welder and allow the upset cylinders to move the two halves together or apart.
A horizontal cylinder is mounted between each pair of frames and these cylinders provide the clamping
force to attach the welder to the rails. Ratio of clamping force to upset force is in excess of 2.2:1.
Contact with the rail is by means of chrome copper inserts mounted in a chrome copper carrier. These
electrodes can be readily changed to suit different rail sizes.
By use of adjustment
shims under the
electrode insert, rail
alignment to within ±
0.2mm can be
achieved.
The horizontal
clamping cylinders
system compensates
for electrode wear and
ensures that the
clamping/upset ratio is
always constant.

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H1000 GENERAL ARRANGEMENT
Welder Head Front View
1. Operators Control Console 2. Left Front Quadrant With 3. Right Front Quadrant
Transformer Inside
4. Front Upset Cylinder 5. Center Axle & Shield 6. Upset Rod and Shield
7. Upset Cylinder Cap Pressure 8. Hydraulic Manifold 9. Hoses with Fireproof Coating
Gauge
10. Welder Head Suspension 11. Cooling Water Flow Meter 12. Upset Cylinder Rod Pressure
Gauge
13. Right Clamp Cylinder Trunion 14. Left Clamp Cylinder Trunion 15. Pipe Rack
16. Hydraulic System Pressure 17. Shear Die Closure Cylinder

Gauge
WELDER SHOWN WITHOUT SHEAR DIE MECHANISMS AND DIE FOR CLARITY

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Welder Head Right End View
1. Operators Control Console 2. Rear Upset Cylinder 3. Front Upset Cylinder

4. Hydraulic Manifold 5. Solenoid Stacks 6. Shear Pressure Gauge
7. System Pressure Gauge 8. Reference Block 9. Electrode
10. Cooling Water Flow Meter 11. Pipe Rack 12. Plug K2
13. Plug K3 14. Plug K4 15. Right Clamp Cylinder
16. Left Clamp Cylinder 17. Right Front Quadrant 18. Right Rear Quadrant
19. Quick Disconnects
16 19
1 11
10
7
15
17
5
6
18
12
4
13
19
14
8
9 9
3 2

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Welder Head - Rear View
1. Operators Control Console 2. Welder Head Suspension 3. Solenoid Stack

4. Rear Upset Cylinder 5. Cooling Water Hoses 6. Cooling Water Flow Meter
7. Left Clamp Cylinder 8. Right Rear Quadrant 9. Center Axle and Shield
10. Left Rear Quadrant with 11. Left Clamp Cylineder Trunion 12. Quick Disconnects, Hydraulics
Transformer inside
13. Quick Disconnects, Cooling 14. Umbilicals In Fire Proof Cover 15. Rear Upset Rod and Shield
Water
16. Right Rear Quadrant 17. Shear Die Closure Cylinder 18. Position Transducer
(Rear)
19. Pipe Rack
3 16 12 1 19 2 11 7 6
13 4 14 5 8 17 15 9 10 5 18
WELDER SHOWN WITHOUT SPARK FLAPS ORSHEAR DIE MECHANISMS AND DIE FOR CLARITY

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Welder Head Left End View
1. Operators Control Console 2. Welder Head Suspension 3. Left Clamp Cylinder

4. Name/Serial Number Plate 5. High Voltage Connection 6. High Voltage Cables
Insulator
7. Cooling Water Hoses 8. Transducer Housing 9. Left Front Quadrant
10. Cooling Water to Left Front 11. Pipe Rack 12. Cooling Water Flow Meter
Welding Transformer
13. Proximity Switch Cable 14. Left Rear Quadrant 15. Cooling Water to Left Rear
Welding Transformer
16. Proximity Switch 17. Hydraulic Hoses with 18. Reference Block
Fireproof Covering
19. Electrode
11 1
12 2
13 17
7 3
66 4
5 5
66
66
16 8
14 18
15 10
19 19
WELDER SHOWN WITHOUT SPARK FLAPS OR SHEAR DIE MECHANISMS AND DIE FOR CLARITY

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Welder Head Suspension Components
1 Suspension Chain
2 Swivel Assembly & Connections
3 Bale Link Assembly
4 Links
5 Shackles
6 Pins and Cotters
6
3
6
6
4
4
6
6
5
5
6
6
H-1000 (K920) shown

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INTERNAL SHEAR DIE MECHANISM, GENERAL ARRANGEMENT
1 Shear Die Open/Close Hydraulic Cylinders, Hoses and Fittings (Both Sides)
2 Linkage (Both Sides)
3 Pivot Pins and Cotters (Both Sides)
4 Bell Crank (Both Sides)
5 Adjustable Links (Turnbuckles) (Both Sides)
6 Shear Die
7 Suspension Chains (Both Sides)
8 Suspension Bracket
DO NOT USE ANY LUBRICANTS IN THIS AREA
6 2
6
3
4
5

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WELDERHEAD LUBE DIAGRAM
UPSET ROD & QUICK DISCONNECT RIGHT REAR UPSET HYDRAULIC

SHIELDS SWIVELS CYLINDER MANIFOLD
LEFT REAR RIGHT REAR

PIPE RACK QUADRANT QUADRANT
PROXIMITY
SWITCH
POSITION
TRANSDUCER
LEFT FRONT RIGHT FRONT

QUADRANT QUADRANT
LEFT CLAMP
CYLINDER
REAR
LEFT RIGHT
RIGHT RIGHT FRONT
CENTER AXLE & UPSET ROD & CONTROL CLAMP UPSET
SHIELDS SHIELDS PANEL CYLINDER CYLINDER
FRONT
Figure # 1 – Welder Head Lube Diagram
WELDER HEAD LUBE POINTS TABLE
NUMBER
ASSEMBLY GENERAL LOCATION FIGURE # REF.
OF POINTS
CENTER AXLE 3 FIRE BOX, 3
CENTER AXLE 2 LEFT END (POSITION SENSOR BOX) 8&9
CENTER AXLE 3 RIGHT END (HYDRAULIC MANIFOLD) 6&7
UPSET RODS 4 • FIRE BOX, (2) (ONE EACH SIDE) 3&5
CLAMP CYLINDER AXLES 4 LEFT CLAMP CYLINDER 1&2
CLAMP CYLINDER AXLES 4 RIGHT CLAMP CYLINDER 1&2
WELDER SUSPENSION ATTACHMENTS 8 FIRE BOX 4
COOLING WATER QUICK DISCONNECT
2 PIPE RACK 4
SWIVELS CONNECTIONS
TOTAL 37

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WELDER HEAD LUBE POINTS (DETAIL)
5 5 5 5
FIGURE # 2 - CLAMP CYLINDER, FIGURE #3- CLAMP CYLINDER,

ROD END ROD END
FIG. 3 FIG. 4
FIG. 2
FIGURE # 4 – COOLING WATER

UMBILICAL QUICK DISCONNECT
SWIVEL CONNECTIONS

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WELDER HEAD LUBE POINTS (DETAIL) CONTINUED
CENTER UPSET
AXLE AND ROD AND
SHIELDS SHIELD
1
CENTER
AXLE AND
1
SHIELDS
4 UPSET
ROD AND
4 SHIELD
Figure #5: FIRE BOX LUBE Figure #6: FIRE BOX LUBE
POINS (FROM FRONT) POINS (FROM BACK)
6 UPSET CENTER 6
ROD AND AXLE
SHIELD
FIG. 6
FIG. 7
FIG. 5
1 1 1 6
Figure #7: FIRE BOX LUBE POINS (FROM TOP)-
Including suspension linkage points.

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WELDER HEAD LUBE POINTS (DETAIL) CONTINUED
2 2 2
OPERATOR’S HYDRAULIC
CONSOLE MANIFOLD
POSITION
TRANSDUCER
Figure #8: LEFT SIDE, POSITION

TRANSDUCER END
3 3 3
Figure #9 Figure #9: RIGHT SIDE,

UPSETCYLINDER & HYDRAULIC
MANIFOLD END
Figure #8

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ELECTRICAL SYSTEM GENERAL DESCRIPTION
A Diesel generator (480/3/60) set rated at 365 KVA provides the power for the welding process and all
auxiliary operations.
Single phase power is controlled from the electronic power logic system. The control of the voltage is
by means of two large capacity SCR devices. Special control cards are used to control the voltage
output. These control cards are complete with the necessary safety and control devices to ensure
correct welding voltage parameters are maintained.
Process control is by means of a controllers operating in conjunction.
The basic function of the control system is to provide the necessary voltage in accordance with the pre-
set program at a very accurate level, i.e. fluctuation of not less than ± 0.5%.
The control unit can receive modified welding data via an IBM compatible computer interface. This
feature allows for reprogramming when welding with various rail sections and rails with different
metallurgy. The programmable controller has process control program loaded in that maintains a
specific current density at the weld interface. This density is controlled via signals to a hydraulic motion
control valve in the welder operating circuit.
Basic Electrical System Diagram

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HYDRAULIC SYSTEM
An electrically driven hydraulic pump is used in a constant pressure mode to provide power for all
movements of the welding head. Basic head movements are:
• clamping and unclamping onto rails

• moving the clamped rails towards and away from each other
Sequence controlled (via programmable controller) solenoid valves ensure that the process of the weld
production is correct at all times.
Each clamping cylinder is controlled so that both cylinders can only clamp and open in unison. Within
the control system it is possible to release pressure on either cylinder and thus relax (but not open) one
side of the welder unit.
Clamping is initiated by the console switch.
Weld cylinders (upset) operate in unison at all times and are directionally controlled from a single valve.
During the weld process steady flashing phase, the cylinder speed control is by a proportional flow
control valve. This valve controls the welding speed in accordance with the electronic feedback weld
current monitoring system.
At the final phase of the weld cycle (the upset), the control valve is bypassed and the full flow of the
hydraulic pump is directed to the cylinders. This bypass system is also in use for the weld shearing
operation.
Also at the upset and shear stage the pump pressure is increased if necessary to ensure the welder has
the maximum forging force available.
The hydraulic system consists of a 50 HP electric motor driving the pressure compensator pump. The
pump and motor are mounted on top of a 60 gallon reservoir unit. The reservoir is equipped with oil
level warning floats, temperature control switches, level indicators, pressure and return line filters,
breathers and internal magnetic dirt traps.
This pump allows for remote (automatic) pressure control to welder via a proportional relief valve. This
valve system is pre piped and mounted on the reservoir. A high pressure filter system is mounted to the
pump pressure port.

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An external cooling circuit is installed and this consists of a 1HP electric motor driving a hydraulic pump
which circulates oil through a large capacity air/ oil cooler. Flow from the cooler is directed through the
return filter back to tank, thus ensuring constant cooling and filtration.
AIR-OIL
COOLER
Basic Hydraulic System Diagram

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WELDER CONTROL PANEL
1. Emergency Stop Switch 2. Shearing 3. Weld Cycle Run Light

[Green]
4. Weld Cycle Stop Push Button 5. Weld Cycle Start Push 6. Platen Switch
Button
7. High Speed (Hydraulic 8. (Platen) Forward Pilot Light 9. (Platen) Reverse Pilot Light
Pressure) Pilot Light [Amber] [Amber] [Amber]
10 .Rail Clamps Switch 11. Clamp Release 12. Operating Mode Switch
13. Hydraulic Pressure Switch 14. System Fault Light [Red]
14 1
13 3
12 4
5
11
10
9 8 7 6
H-1000 - Welder Control Panel Layout

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Operating controls for the welder are mounted on a panel located on the right hand quadrant. These
controls are as follows:
EMERGENCY STOP BUTTON (RED)
PUSH TO STOP Pressing the emergency stop button cancels

all commands and isolates all power from the
welding head. It also disables all hydraulic
controls.
PULL TO START ALL Emergency Stops must be in the OUT or
“PULL” position in order to start and operate
the welding machine.
SHEARING SELECTOR-SWITCH
MAINTAINED POSITION REGULAR - TENSION

This will provide clamping of the shear die by shear
die cylinders.
CLAMP
No action. Shear die will maintain previous position.
NEUTRAL
This provides unclamping of the shear die by shear

die cylinders
UNCLAMP
Should be in AUTO before the start of the welding

cycle
AUTO

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WELD CYCLE RUN-GREEN LIGHT
MOMENTARY Light illuminates to indicate that the programmed weld

CONTACT’ sequence is underway and when welder is correctly set up for
welding, this light will ‘FLASH’. After initiating the weld cycle
the light stays illuminated through the weld cycle.
WELD CYCLE STOP-PUSH BUTTON
MOMENTARY Depressing this button will stop the weld cycle and shut off
CONTACT’ power to the welding head
WELD CYCLES START-PUSH BUTTON
MOMENTARY Depressing the button initiates the welding sequence.

CONTACT

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PLATEN-SELECTOR SWITCH
SPRING RETURN TO CENTER FORWARD - REVERSE

FORWARD This will move the two halves of the welder
POSITION (spring together to give minimum gap.
return to center).
REVERSE This will move the two halves of the welder

POSITION(spring apart to give maximum gap
return to center)
INDICATING LIGHTS (AMBER): PLATEN FORWARD, REVERSE, AND HIGH SPED SELECTOR SWITCH
ON/OFF FORWARD - REVERSE

FWD. (Forward) Amber light on console lights when Platen
Amber light Selector Switch is held in the “FORWARD”
position. Switch returns to center when
released and light goes out.
REV. (Reverse) Amber light on console lights when Platen

Amber light Selector Switch is held in the “REVERSE”
position. Switch returns to center when
released and light goes out.
HIGH SPEED Amber light on console lights when SETUP

Amber light Selector Switch is placed in the “HIGH
SPEED” position. Light remains on as long as
switch is in the HIGH SPEED position. (HIGH
SPEED switch is not automatic return and
remains where selected.)

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RAIL CLAMPS-SELECTOR SWITCH
WARNING
BEFORE ACTIVATING THE "CLAMP" POSITION MAKE CERTAIN THE RAILS ARE
PROPERLY IN PLACE ON BOTH SIDES.
IMPROPER POSITIONING MAY RESULT IN SEVERE MACHINE DAMAGE.
MAINTAINED POSITION CLAMP - OFF - UNCLAMP

UNCLAMP (Maintained) Activates the hydraulic valve
POSITION and fully opens the clamp mechanism on
both sides.
CLAMP POSITION (Maintained) Activates the hydraulic valve

and fully closes the clamp mechanism.
OFF POSITION Both UNCLAMP and CLAMP solenoids are

de-energized and the hydraulic valves are in
the float position, i.e. cylinders are unloaded
and quadrants are not in contact with rail
NOTE
AFTER WELD START IS ACTIVATED, WAIT ABOUT 5 or 6 SECONDS. (WATCH TIME
ON THE MONITOR). THEN PLACE THIS SWITCH IN “OFF” POSITION

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CLAMP RELEASE – SELECTOR SWITCH
MAINTAINED POSITION LEFT - OFF - RIGHT

LEFT POSITION Clamp Release Left relaxes clamping force
maintained on the Left half of the welding machine.
RIGHT POSITION Clamp Release Right relaxes clamping force

maintained on the Right half of the welding machine.
OFF POSITION Clamp release function is disabled.

maintained manual

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OPERATING MODE-SELECTOR SWITCH
MAINTAINED POSITION TEST - HAND - AUTO

TEST POSITION Allows the welder to run through a full weld
cycle to test hydraulic pressure by allowing
times and speed to be recalibrated
automatically without power applied to the
transformers.
NOTE:
TEST PROGRAM MUST BE RUN AFTER EACH PROGRAM CHANGE
CAUTION
IF THIS TEST MODE IS ACTIVATED, RAIL SECTIONS MUST BE IN EACH
CLAMP AND A GAP OF AT LEAST 60mm MUST BE SET BETWEEN THE RAIL
HAND POSITION: ENDS.
System is in manual mode for setup and the
welding cycle cannot be activated.
AUTO POSITION System is in the automatic mode and is ready

to initiate welding.
CAUTION!!
WHEN THE OPERATING MODE SELECTOR SWITCH IS IN THE "AUTO"
POSITION, WELDING VOLTAGE IS PRESENT AT THE ELECTRODES.

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HYDRAULIC PRESSURE-SELECTOR SWITCH
NOTE:
TO PERFORM WELDING THIS SWITCH MUST BE IN THE "RUN" POSITION.
MAINTAINED POSITION HIGH SPEED SETUP - SETUP - RUN

This will provide low system pressure (500 to
900 psi).
HIGH SPEED
SETUP POSITION
This will provide low system pressure (500 to

900 psi).
SETUP POSITION
This will provide welding system pressure (1500

to 2000 psi).
RUN POSITION

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OPERATING MODE AND HYDRAULIC MODE COMBINATION
NOTE:
COMBINATION
This combination allows move
welder platen forward on high
HIGH SPEED speed under low (500 to 900
SETUP POSITION psi). hydraulic pressure on
welder

welder platen forward on set up
SETUP POSITION (low) speed under low (500 to
900 psi) hydraulic pressure on
welder

welder platen forward on set up
(low) speed under high (1500 to
RUN POSITION
2000 psi) hydraulic pressure on
welder

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OPERATING MODE AND HYDRAULIC MODE COMBINATION
NOTE:
MAINTAINED POSITION
This combination allows reverse
welder platen on high speed
HIGH SPEED under low (500 to 900 psi)
SETUP POSITION hydraulic pressure on welder

welder platen on set up (low)
SETUP POSITION speed under low (500 to 900 psi)
hydraulic pressure on welder

welder platen on set up (low)
speed under high (1500 to 2000
RUN POSITION
psi) hydraulic pressure on
welder

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NOTES

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Section 5
PRODUCT OPERATION

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NOTES

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CAUTION
BEFORE ATTEMPTING TO WELD WITH THE MACHINE, ALL OPERATORS SHOULD BE FAMILIAR
WITH THE SAFETY RULES AS SET OUT IN THE SAFETY SECTION.
WELDER PREPARATION
To ensure good quality welds are produced, the following rail and machine preparation is necessary.
Check that the electrodes (clamps) are clean and clear of weld slag and other debris. Wire brush and
clean as required.
Check that “firebox” and bottom plates are clean and clear of weld slag and other debris. Wire brush and
clean as required.
Remove mill scale and grind the rail webs to bare metal in the areas of clamping (approx 650mm
distance from rail-end); this will ensure a good electrical contact.
NOTE:
Ground rail webs tend to oxidize quickly and the oxidation will prevent good electrical contact. It is
therefore important that welding be carried out within two hours of grinding.
NOTE:
If the rail manufacturer’s identification marks are present int the clamping area, they must be ground
flush with the web. Failure to do this may result in electrode damage and possible
slipping during upset.
Ensure that the rail ends are cut square (±1mm vertical tolerance) and are clean (oil and grease will
prevent initiation of the weld process).

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KEEP IT CLEAN
Weld scale (splatter) cleaning is essential to good operation of the welding machine. Weld slag can
cause:
• Short circuits resulting in arching during welding

• Scoring of the center axle (shaft) and upset rods
• Damage to seal and insulation
Cleaning should be carried out as many times as needed depending on how many weld are carried out
per hour.
Recoat with anti-spatter compound in the “firebox” after each cleaning. Use Protex or equal each time.
Recoat other areas at least once a day.
Recoating speeds cleaning and save time.
Use scraper (sparingly), wire brush and/or air blast.
DO NOT USE WATER

Clean the weld area of the machine. Pay particular attention to the removal of weld splatters in areas of
the shear system clamps (buildup of splatter can cause short circuits).
Before commencing welding or as many times as needed depending on how many welds are carried out
per hour, the welder flash area should be cleaned and coated with Anti-splatter compounds (Holland
recommends “Protect-O-Metal” or “Protex”)
Before commencing each shift, ensure that the welder shafts and pivot points are adequately greased
(see lubrication chart).

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WELDING PROCESS
General Description
The rails to be welded are clamped by the machine in a pre-determined position. Alignment of the rail is
automatic within the machine.
The rails are moved towards each other by the upset cylinders at a pre-determined speed (approx
0.00…20 mm/sec). As the rails approach each other, a specific voltage is applied to the rails and a
welding contact is produced. Control of the welding process includes voltage level variation according
to a specific program. Speed of the rail movement is also controlled to ensure a constant welding
current is maintained.
The normal weld process can take up to 200 seconds (depending on rail section). During the welding
process, up to 45 mm of rail material can be consumed. The welding procedure consists of the
following general stages:
1. Position machine on rails

2. Clamp and align
3. Initiate welding process which consists of the following stages:
a. Pre-heat stage
b. Steady flashing stage
c. Boost stage (acceleration)
d. Upset stage
e. Forging stage.
f. Shearing stage
4. Release machine from rails

To ensure good quality welds are produced, the following machine and rail preparation is necessary.

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CLAMP ANGLE CHECK PROCEDURE
Overview
The welder head is designed to clamp onto the web of a railroad rail during the welding process.
Clamping provides firm electrical contact between the electrodes and the rail, holds the rail
secure during flashing and provides the pulling force necessary for upset. (See Fig. # 1)
Clamping force is generated through a mechanical linkage operated by hydraulic cylinders.

Each welder head has two cylinders.
Figure #1 – Clamp Cylinder Layout

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Clamping Forces
To clamp, the piston moves down. As the piston & rod moves down it acts on a system of links
and pins that connect the rod end to the welder head quadrants. As the piston and rod move
down, the clamp cylinder spreads apart (See Fig. #2). The end connected to the welder head
quadrant moves out multiplying the force and pushing against the quadrant. As force is applied
downward by the clamp cylinder and linkage, the upper part of the quadrants are forced away
and pivot around the center shaft. This motion again multiplies the force of the clamp cylinders.
The multiplied force is transmitted to the lower end of the quadrant and against the rail as
clamping force.
Clamping Angle
Clamp angle refers to the angle between a line drawn through the centers of the pins in the
crosslink and a line drawn through the centers of the pins in the crosslink pins and the centers of
the pins in the head quadrants. This type of measurement would be impossible in the field, so
another system has been developed and will be descried below. (See Fig. # 3 & 4)
FORCE FORCE
PISTON & ROD

MOVEMENT
Figure #2 – Clamp Cylinder Forces
Figure # 3 – Clamp Angle with Figure #4 – Clamp Angle with Welder

Welder Head Not Clamped on Rail Head Clamped on Rail

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SYSTEM PRE-CHECK PROCEDURE
Check System Pressure
Clamp Pressure System Force

Welder head
PSI BAR PSI BAR
H1000 1800 112 2200 151
4
1. Start power skid and main hydraulic pressure pump. Allow pressure to build and
monitor by means of the main pressure gauge on the power skid. Adjust as needed to
achieve proper system pressure for the welder head being used.
2. Put the Hydraulic Pressure switch to “RUN”
3. Check hydraulic system pressure gauges to be sure system pressure is

at the proper levels for the welder head being used. (See Fig. # 5)
4. Adjust pressure settings as needed to achieve desired levels.
IMPORTANT NOTE:
System pressure must be set FIRST. If system pressure is not at proper levels clamp
pressure may be set improperly resulting in serious damage to the welder head during
operation.
5. Check the reading of system hydraulic pressure gauge on the welder head. If system
hydraulic pressure is not at proper setting, determine cause and make the necessary
repairs and/or adjustments. (See Fig. # 5)
SYSTEM
PRESSURE AT
WELDERHEAD
SHEAR
PRESSURE
Figure #5-Pressure Gauge Locations

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Measure Clamp Angle
Clamp angle can be determined by increasing distance between cross head and top of the
clamp cylinder.
WARNING
If the measurements are less than the minimum acceptable limit action must
be taken immediately. Once the clamp angle falls below the minimum limit 1/2”
(12.7 mm) the forces generated by action of the clamping mechanism becomes
so great that the welder head may be damaged or destroyed. by cracking.
Failure to make adjustments and/or repairs may result in catastrophic

damage to the welder head or possibly its total destruction due to cracking
and bending.
1. Raise the welder head clear of the ground and any obstruction.
2. While suspended “Clamp” the head without a rail.
3. With the welder head in full clamp mode measure the distance between the block fitting
and the top of the rod (See Fig. # 6). The measurement may not be the same from one
cylinder to the other on the same machine
4. Record the measurements for future reference. (See Fig. # 6). Usually this distance
represents bottomed up clamp cylinders.
5. Open (unclamp) the welder head and lower onto a rail.
6. Clamp the machine onto the rail and “clamp up’ as you would during a normal weld.
Figure #6 Clamp
Angle-No Rail

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7. Once the machine is clamped onto the rail, measure the “clamp angle” at the same points as
before. (See Fig. # 7)
Figure #7 Clamp
Angle-With Rail
8. See calculation of clamp angle in step 9.

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9. CLAMP ANGLE CALCULATION CLAMP

ANGLE
MEASUREMENT=X
CLAMP
CYLINDER
WELDERHEAD CLAMPED – NO RAIL
CLAMP
ANGLE
MEASUREMENT=Y
CLAMP
CYLINDER
WELDERHEAD CLAMPED ON RAIL

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10. Subtract the first measurement from the second for each cylinder. The number derived
represents the clamp angle.
X = Measurement, Welder Head clamped-

NO RAIL
Y= Measurement, Welder Head clamped-

X ON RAIL
Y Z=Clamp Angle
X-Y=Z
The measurement should be in a range between 3/4” (19 mm) to 3/8” (10mm). Once the
measurement falls below the minimum, the electrodes MUST be shimmed or the inserts
replaced. Which of these options to follow is a judgment call for the supervisor/operator based on
experience, but action must be taken at that time or within a reasonable time.
Much of the cause for the changes in the measured clamp angle are due to wear of the electrode
inserts. These inserts are intended to be the points of contact with the rail instead of the electrodes.
If inserts are allowed to wear too much the socket head cap screws that attach them to the electrode
and welderhead quadrant may be damaged to the point where special (and time consuming)
methods may be necessary to remove them. screws electrodes themselves may be damaged
is important to remember that the measurement may not be the same from one “side” (or cylinder)
to the other on the same machine when clamped on a rail. This is due to uneven wear of the
electrode inserts and other factors.
11. Record the measurements for future reference.
The operator may decide to make a keep a record of the measurements for future reference. Over
time, a review of the numbers may show a trend in wear that may help the operator predict when
shims or insert replacement may be needed. This may help to avoid costly down time waiting for
parts or damage to the welder head.
12. If measurements are within acceptable limits, no further action is necessary and the
welderhead can be unclamped and returned to storage aboard the truck or begin work. If
measurement results are below acceptable limits, electrodes inserts must be replaced or
electrodes shimmed.

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RAIL PREPARATION
Note: The details of the following sequence and description may differ from your operation due to
differences in rail, weather, specifications or other items. Please consult your local operational
requirements and procedures for questions
STEP TASK REMARKS

1 Remove clips (spikes) for a minimum of
four sleepers (ties) or six feet (6’) on
either side of welding site (joint)
2 Prepare ends of rails.

Ensure that the rail ends are cut square
(+/-1mm vertical tolerance) and are
clean (oil and grease will prevent
initiation of the weld process) and free
of defects.
KEEP IT CLEAN
Remove mill scale and grind (polish)
rail webs to base metal in the areas of
clamping at a distance of 26 inches
(660 mm) on both sides of the rail on
both rail ends. This will ensure a good 26” (660 mm) min. 26” (660 mm) min.
electrical contact.
NOTE: Ground rail webs tend to

oxidize quickly and the oxidation will
prevent good electrical contact. It is
therefore important that welding be
carried out within two hours of grinding.
NOTE:
If the rail manufacturer’s identification
marks are present in the clamping
area, they must be ground flush with
the web. Failure to do this may result
in electrode damage and possible
slipping during upset.

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STEP TASK REMARKS

3 Position the rails to be welded to within ≥ 2 - ≤ 3 mm GAP
2 - 3 mm (0.078 – 0.118”) of each (≥ 0.078” – ≤ 0.118”)
other.
4 Use straight edge and taper gauge to

determine “CROWN” of rail.
Place the straight edge on the top of

the rail with the notch over the gap.
Ensure edge is as vertical as possible
5 Rock until the bottom of the straight

edge makes contact with the head of
the rail on one side.
6 1. Place straight edge on one side with

notch over gap.
2. Place taper gauge on the rail head

under opposite end and push in until
it makes contact with the bottom of
the straight edge. ≤ (0.0120”/
0.30mm)
3. The gauge should register not more
than one hundred and twenty
thousandths of an inch
(0.0120”/0.30mm) .

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STEP TASK REMARKS
7 Use straight edge to determine “KINK”
misalignment in between rails. Rails
must be set straight.

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WELDING SEQUENCE
Once the automatic welding cycle has been initiated, the control system goes through the
following sequence.
1. Selects and feeds voltage reference signal to the voltage controller.
2. Monitors the current position of the PLATEN cylinder and its subsequent movement
via a linear distance transducer.
3. Starts timer or distance circulation.
4. Sends required PULL cylinder velocity reference to the proportional valve amplifier
card.
5. Changes voltage signal to voltage controller in reference to welding parameters and

actual stages of welding cycle.
6. Controls UPSET CYLINDER movements via the proportional valve amplifier card.
7. Initiates signal to proportional valve to allow acceleration for UPSET CYLINDER on

BOOST stage.
8. Activates UPSET velocity by energizing the high speed bypass valve.
9. Maintains voltage signal reference to the voltage controller until a preapproved time is
reached at UPSET stage.
10. Stops UPSET cylinder when required UPSET without welding current is reached.
11. Starts flash removal process after waiting for the weld forging time.
12. Complete automatic welding cycle at the end of the flash removal process

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THE WELDING SEQUENCE-DETAILED
The Welding Control System (PLC) controls the welding machine to make a weld. The welding
cycle is automatic. The generator supplies required electrical power. Weld Management
System (WMS) records and reports the welding results.
The welding cycle has five (5) stages:

• Preflash
• Flash
• Boost
• Upset
• Forge
• Preflash is the initialization stage of the welding cycle. It allows the weld to start with
square rail ends.
• Flash is the stage of stable flashing when parts are heated to required temperature
distribution.
• Boost is the stage of accelerated flashing that prepare rail ends to upset stage
• Upset is a stage of welding cycle when heated rail ends are pushed together to obtain a
welding joint.
• Forge is a stage after upset when hot joint is held in the welder to cool down.
• The Weld Management System program analyzes the data collected from sensors during
welding process and compares it to the standards and parameters entered for the job. If
the weld data s within the limits set the system displays “OK” on the computer monitor and
stores the data in memory.
• If the weld is not within specification the system will display an “X”. If the weld is failed, it
should be cut out and must be re-welded after the cause is determined.
• Welder provides automatic shearing of reinforced metal after upset. It is automatic and
controlled by PLC.
• When shearing operation is complete, the welding machine is lifted off the rail and the
sheared flash is removed before it can cool to the point it is cold and solid.
• When the flash is removed the operator will check the welded rail for visual defects.
Straightness of weld is checked by the straight edge. At this point the weld may be
inspected by an authorized manager or inspector. If the weld is approved the operator will
make preparations to move to the next weld.

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SETUP AND WELD
STEP TASK REMARKS

8 Place the “OPERATING MODE” switch on
the welder control panel to the "HAND"
position.
9 Place the “HYDRAULIC PRESSURE”

selector in the “HI-SPEED SETUP”
position.
10 Open the welder clamping mechanism by

placing the “RAIL CLAMPS” selector switch
to “UNCLAMP”.

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STEP TASK REMARKS

11 Activate the upset cylinders
by holding the “PLATEN”
switch in the “REVERSE”
position and retract the
welder halves to the fully
open position.
Amber light “REV” on

console lights as long as
switch position is held.
12
Move the SHEARING
selector switch to
“UNCLAMP” position
(SHEARS ARE OPTIONAL

EQUIPMENT)
13
Lower the welder over the
rails until all reference blocks
are resting on the rail.
Do not place full load of

welder on rails

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STEP TASK REMARKS

14 Close the clamping cylinder by activating
the “RAIL CLAMPS” selector switch to
the “CLAMP” position in progressive
stages
This will ensure that uneven clamping

does not take place. In particular, check
to ensure the shear device does not
"hang up" on the rail during clamping.
CAUTION
IF SHEAR "HANGS UP", REVERSE THE CLAMPING PROCEDURE IMMEDIATELY.
SEVERE DAMAGE CAN OCCUR IF CLAMPING CONTINUES WHEN THE SHEAR IS
"HUNG UP", OR THE RAILS ARE NOT CLAMPED EVENLY.
STEP TASK REMARKS

15 If uneven clamping is indicated, open
clamps, and re-clamp.
If uneven clamping is still indicated the

electrodes may require shimming, (See
trouble shooting procedure).
STEP TASK REMARKS

16 Place “SHEARING” Switch to “AUTO”
Position. Ensure shear die is closed
properly.
(SHEARS ARE OPTIONAL

EQUIPMENT)

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STEP TASK REMARKS

17 Turn the “HYDRAULIC PRESSURE”
selector switch to “RUN”.
WARNING
BEFORE ACTIVATING THE "CLAMP" POSITION MAKE CERTAIN THE RAILS ARE
PROPERLY IN PLACE ON BOTH SIDES. IMPROPER POSITIONING MAY RESULT IN
SEVERE MACHINE DAMAGE
STEP TASK REMARKS

18 The system pressure gauge should react
with an increase in pressure and stop at a
pre-set value.
19 Lower spark shield flaps on BOTH SIDES

of welder head.

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STEP TASK REMARKS

20 Place the “OPERATING MODE” selector
switch to the "AUTO" position.
Voltage value will display on monitor and

“WELD CYCLE RUN” light should begin
flashing to indicate that the programmed
weld sequence is underway and when
welder is correctly set up for welding.
CAUTION
WHEN THE OPERATING MODE SELECTOR SWITCH IS IN THE"AUTO" POSITION,
WELDING VOLTAGE IS PRESENT AT THEELECTRODES.
STEP TASK REMARKS

21 Press the "WELD CYCLE-START"
button. This will initiate the welding
sequence in automatic mode.
STEP
STEP TASK REMARKS

22 After initiating the weld cycle the “WELD
CYCLE RUN” light stays illuminated
through the weld cycle.
NOTE: The PRE-HEAT phase flashing will be erratic and high currents will be observed.
After a short period, the current will stabilize and the steady state flashing process will
commence.

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STEP TASK REMARKS
23
Once the weld cycle begins and the weld
monitor indicates that the welding is in
progress,(4 to 10 seconds on the
monitor) turn the “RAIL CLAMPS” switch
to the “OFF” position. This will prevent
the welder re-clamping at the end of the
program cycle.
STEP TASK REMARKS

24
OBSERVE PROPER SAFETY
PROCEDURES!!
Stand AWAY from welding machine

during welding process.
Do not stand directly in line of “firebox”

area of welder during welding process.
Locate yourself near EMERGENCY

STOP BUTTON and observe weld
cycle.

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STEP TASK REMARKS

25
OBSERVE PROPER SAFETY
PROCEDURES!!
Monitor area around welding machine

for fires started by sparks.
Ensure no fires start in ballast, or

sleepers (ties)
26 Quench all fires immediately with

appropriate extinguisher equipment.
27 On completion of weld and shearing stage

unclamp the shear die. At this point the
following procedure should be followed
28 (a) Place the “OPERATING MODE”

selector switch into the “HAND”
mode.

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STEP TASK REMARKS
29 (b) Place the “HYDRAULIC PRESSURE”
selector switch into the “HIGH SPEED
SETUP” mode.
30 Amber light (HIGH SPEED) on console light

is on as long as switch position is
selected for “HIGH SPEED”.
31 (c) Place the “SHEARING” selector switch

into the “UNCLAMP” position.
(SHEARS ARE OPTIONAL EQUIPMENT)
32 (d) Place the “RAIL CLAMPS” selector

switch in the “UNCLAMP” position.
33 Lift the welder clear from the weld and

remove the sheared flash material from
the rail.

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STEP TASK REMARKS

34 Preliminary alignment check after the
weld:
(a) Rock the bottom of the straight edge

on the rail until it makes contact with
the head of the rail on one side.
STEP TASK REMARKS

35 (b) Place straight edge on one side with
notch over weld. Check weld for
steps horizontal or vertical.

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STEP TASK REMARKS
36 Hold the “PLATEN”-selector switch in the
“REVERSE” position and open the welder to
its maximum position.
Amber light (REV) on console lights as long

as switch position is held.
STEP TASK REMARKS

37 Clean weld spatter from the inside of the
welder.
38 Recoat inside of weld with anti- spatter

compound as needed. Use PROTEX or equal.
Unit is now ready for the next weld.

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Section 6
PRODUCT MAINTENANCE

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NOTES

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MAINTENANCE INSTRUCTION-GENERAL
Step Item Task Remarks

1 Hydraulic fluid Check hydraulic fluid level in Full, Clean
reservoir before starting Add as needed.
engine.
DO NOT OVER FILL
2 Coolant fluid Check fluid level in chiller Full, No Rust

(refrigeration) unit if so Add as needed.
equipped before starting
engine. Add as needed.
DO NOT OVER FILL
3 Upset Rods Before the start of each shift, Grease all

grease upset rods, center
axle, travers rods, clamp
cylinder axles and
suspension anchorage.
Apply lubricants to the Reference Lube Diagram
suspension point.
4 Weld spatter Remove weld spatter from

the shear die and linkage,
upset rods and center axles
and shields, welder body
faces in fire box

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Step Item Task Remarks

5 Weld Before each shift starts, ensure
Management that the weld management
System system computer has enough
storage capacity for the shift
welding data, that there is
sufficient storage media and
printer supplies (if so equipped)
for proposed production levels.
6 Electrodes Wire brush electrodes before Clean AFTER EACH WELD
shift and after every 3 or 4 welds
(more often as production and
materials dictate) to ensure
good electrical contact.
7 Electrodes Clean electrodes with Emery More often as conditions and materials
cloth or buff lightly with sanding dictate.
disk at least twice each shift.
8 Anti- Spatter Coat all “firebox” surfaces with Apply after every 6 to 8 welds. More often
anti-spatter compound as dictated by rail and conditions.
9 Electrode Ensure that electrode contact

surfaces are free of scale,
corrosion and or oil before
clamping welderhead onto rail.
10 Procedure Do not clamp on different size Will cause severe welder damage.
rails with the welding machine.

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MAINTENANCE
The machine must be maintained on a systematic basis to ensure efficient operations.
Maintenance procedures are to be carried out on the following basis:
• Shift inspection/maintenance
• Daily inspection
• Weekly inspection/maintenance
• Monthly inspection/maintenance
• Semi-annually
• Annually
• 18-months
• Bi-annually
• 5-years
Regular grease application is essential and it is important that the points indicated on the lubrication
chart are greased in accordance with the schedule and as necessary.
Before any maintenance work is performed under the welder, insure that the welder is supported on a
certified welder stand or on the ground secured with safety bars.
Interpretation of duty cycles vary widely. The values below should be considered as a guide. For
engine and other high stress components, refer to manufacturer documentation for their definition of
service intervals.

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Shift Maintenance
This procedure should be carried out before and after each shift and before starting work at a new site.
Check fluid levels in engine and generator.
Do a visual inspection of the machine, cables, hoses, crane, power cabinet. Clean and correct any
obvious damage, leaks or broken components.
Check the cooling system and ensure fluid levels are correct. Add fluid as necessary.
Check the hydraulic system for fluid level and condition of filters. Add fluid and replace filters as
necessary. Check all system hoses for leaks; clean as necessary.
Perform the routine lubrication function in accordance with lubricating chart.
Clean the welding splatter from the machine and coat with non-sticking compounds.
Clean the upset rods and axles and ensure that slag and splatter have not built up around the shields
and shear guide.
Check the condition of the shear cutting edges. Re-grind or replace as necessary.
Clean electrode surfaces with wire brushes and emery cloth.
Step Item Task Safety Remarks

1 Machine, Visually inspect the Clean and correct any
cables, machine, cables, obvious damage,
hoses, hoses, crane & power spills or broken
crane, cabinet. components.
power
cabinet

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2 Welding Check the cooling at Add fluid as necessary
Coolant sight glass and ensure
system fluid levels are correct.
DO NOT OVER FILL
3 Genset Check the cooling at Add fluid as necessary

Coolant sight glass and ensure
system fluid levels are correct.
DO NOT OVER FILL
4 Hydraulic Check the hydraulic Add fluid as

oil level system for fluid level necessary.
DO NOT OVER FILL
5 Hydraulic Check filter condition Replace filters as

system indicators necessary.
filters
6 Hydraulic Check all system Repair leaks and

system hoses for leaks; clean as necessary
hoses

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7 Lubrication Lubricate all fittings. Grease all (Ref. Lube
Diagram)
Refer to lube chart.

Clean up all excess
grease from fittings
8 Fire box Clean the welding

area splatter from the
machine and coat with
non-sticking
compounds
9 Upset rods, Clean the upset rods

Center and axles and ensure
Axle that slag and splatter
(Center have not built up
Shaft), around the shields and
Shields shear guide
10 Shear die Check the condition of Re-grind or replace as

the shear cutting necessary.
edges.
11 Electrodes Clean electrode
surfaces with wire
brushes and emery
cloth.
12 Shear die Check shear die

suspension suspension cylinders
cylinders and linkage
and linkage

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13 Anti- Coat the welding area
Splatter with non-sticking
Compound compounds.
14 Emergency Make sure that ALL

Stops emergency stops are
pulled out.
15 Fire Ensure that fire
Extinguish extinguishers are in
ers place, charged and
have current tag.
Seal and Safety Pin in
place. Pressure gauge
indicates FULL
CHARGE.
16 Generator Ensure that screen are
ventilation not obstructed
screens
17 Welder Check welder
Suspensio suspension
n

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Daily Maintenance
This procedure should be carried out daily and before starting work at a new site
Check engine air cleaner and replace as needed
Check hydraulic oil level. Fill as needed to proper operating level.
Operate the crane through all axes.
Check the tension and condition of the drive belts.
Check the engine intake piping. Tighten hose clamps as necessary.
Check to ensure that fan and radiator guards are in place and secured. DO NOT OPERATE MACHINE
WITHOUT GUARDS IN PLACE.
Check for cracks, loose rivets, bends and loose fan blades. Be sure fan is secure. Tighten with screws
as necessary.
Check Genset engine oil level. Fill as needed until operating level is reached.
Check for leaks on ALL the hose connections
Check hydraulic high pressure filter restriction indicator and replace as needed
Check all hydraulic lines for leaks. Ensure NO LEAKS!
Check hydraulic return filter restriction indicator. Replace as needed
Ensure Main control panel vent fans. (mounted to lower door interior) are functioning. Monitor air flow at
upper panel vents.
Ensure upper and lower panel vents are not obstructed
Using controls on welder head operator’s panel, exercise welder head to ensure function of all the
mechanical and hydraulic components.
Inspect exhaust system for loose clamps or damage between the intake air piping, air cleaner,
turbocharger, charge-air cooler, and intake manifold. Replace any damaged pipes, and tighten loose
clamps.
Check engine for all wire connections and the wiring harness for damage.

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Step Item Teak Safety Remarks

1 Check engine Check indicator,
air cleaner Replace as needed.
restriction
indicator
2 Check Check hydraulic oil is Refer to
hydraulic oil level at FULL mark manufacturer’s
level Add as needed until documents for proper
Hot surface
operating level is viscosity and operating
reached. ranges.
DO NOT OVER FILL Do not substitute
Confined spaces
Obstructions
Sharp edges
3 Crane Operate crane through
function. all axes.
Struck by
Caught between
4 Drive belts Check Tension and Longitudinal (direction
condition of belt length) cracks
that intersect with
transverse cracks are
not acceptable.
Replace the belt if it is
frayed or has pieces of
material missing
5 Engine air Visually inspect the Tighten hose clamps
intake piping intake piping daily for as necessary
wear points and Torque Value: 8 Nem [
damage to piping, 72 in-lb
loose clamps, or
punctures that can
damage the engine.

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Step Item Task Safety Remark

6 Fan and Check to ensure that DO NOT OPERATE
radiator fan and radiator guards MACHINE WITHOUT
guards. are in place and GUARDS IN PLACE
Hot surface
secure.
Repair or replace as
needed
Rotating parts
Confined spaces
Obstructions
Sharp edges
7 Fan blades Check for cracks, loose Replace original
and hub rivets, and bent or equipment fan that is
loose blades. damaged with a fan of
Check the fan to make Confined spaces the identical part
sure it is secure Obstructions number.
Tighten the cap Sharp edges
screws, if necessary.
8 Genset Check oil level at FULL Refer to
engine oil mark manufacturer’s
level. Add as needed until documents for proper
Hot Surface
operating level is viscosity and
reached. operating ranges.
DO NOT OVER FILL Do not substitute
Confined spaces
Obstructions
Sharp edges
9 Hose Check all the hose
connections connections.
Ensure NO Leaks
Hot Surface
Confined spaces
Obstructions
Sharp edges

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10 Hydraulic Check hydraulic high
high pressure pressure filter
filter restriction indicator.
Hot Surface
restriction Replace element as
indicator. needed
(pop-up)
Obstructions
Sharp edges
11 Hydraulic Check all hydraulic
lines for lines for leaks. Ensure
leaks. Ensure NO LEAKS.
Hot hydraulic fluid
NO LEAKS.
High pressure
hydraulic oil.
12 Hydraulic Check hydraulic return
return filter filter restriction
restriction indicator.
Hot surface
indicator. Replace as needed
(gauge)
Confined spaces
Obstructions
Sharp edges
13 Main control Ensure vent fans
panel vent (mounted to lower door
fans interior) are functioning.
Monitor air flow at Obstructions
upper panel vents Sharp edges
14 Upper and Ensure upper and
lower main lower panel vents are
control panel not obstructed.
vents Obstructions
Sharp edges
15 Test weld Run test weld (If Required)

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16 Welder head Using controls on
function of all welder head operator’s
mechanical panel, exercise welder
and hydraulic head to Struck by
components. Ensure function of all Caught between
mechanical and
hydraulic components.
17 Air Leaks, Air Inspect for loose Use proper
Intake and clamps or damage replacement parts
Exhaust between the intake air Do not try to repair
Hot surface
Systems piping, air cleaner, damaged parts
turbocharger, charge-
air cooler, and intake
manifold
Replace any damaged Confined spaces
pipes, and tighten Obstructions
loose clamps. Sharp edges
18 Engine Wiring Check all wire Faulty wiring can

Harness connections and the cause improper
wiring harness for engine operation and
High voltage
damage.. poor performance.
Confined spaces
Obstructions
Sharp edges

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Weekly Maintenance
Visual inspection of the machine, cables, hoses, crane, power cabinets, recording devices, engine and
generator.
Checking of the refrigerant unit for fluid levels, system pressure and flow.
Cleaning of all surfaces, including rods, shields, covers, etc.
Removal of all welding splatter, slag, etc.
Coating of the welding area with non-sticking compounds.
Inspection and cleaning of electrodes (ensure power is off)
Alignment of the electrodes is checked by use of straight edge (ensure power is off).
All electrode fixing screws tested for tightness (ensure power is off).
Upset rod collars checked for tightness (ensure power is off).
Clamping cylinder collar checked for tightness (ensure power is off).
Bottom cover removed to allow inspection of secondary circuits (ensure power is off).
Check secondary circuits for oxidation or burning. Clean up any such spots with emery cloth.
Check all electrode and conductor fastenings for tightness.
Check cooling system clamps and ensure they are tight.
Move bottom covers. Clean and inspect inside conditions.
Check each transformer resistance. This should be not less than 1.0 Mega Ohm when checked with a
500 V mega ohm meter. If resistance is incorrect, the transformer must be heated (dried) until correct
level is reached.
Clamp a new set of reference rails in the machine and check:
Alignment – shim as required
Operate the machine in test mode and time the flashing speed, upset speed and weld periods. If any
parameters are incorrect, adjust as necessary.

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1 Cables, Visually inspect the Repair leaks and
hoses. machine, cables, clean as necessary
hoses.
2 Fluid Check fluid levels, c Add fluid as necessary

Levels
DO NOT OVER FILL

3 System Check system
Pressure pressure.
4 Clean Clean all surfaces,

including rods, shields,
covers, etc.
5 Clean Remove all welding

splatter, slag, etc

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6 Inspect Inspection and ENSURE
and Clean cleaning of electrodes POWER IS OFF
7 Check the Alignment of the ENSURE

Following electrodes is checked POWER IS OFF
by use of straight edge.
8 All electrode fixing ENSURE

screws tested for POWER IS OFF
tightness.
9 Remove bottom plates ENSURE

on all four quadrants to POWER IS OFF
allow inspection of
secondary circuits

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10 Upset rod collars ENSURE
(yokes) checked for POWER IS OFF
tightness (ensure
power is off).
11 Check secondary ENSURE Clean up any such

circuits (shunt straps) POWER IS OFF spots with emery
for oxidation or cloth.
burning.
12 Check all electrode and ENSURE

conductor (shunt POWER IS OFF
straps) fastenings for
tightness.
13 Check cooling system Repair leaks and

clamps and ensure clean as necessary
they are tight.
14 Replace the bottom

covers.
15 Clamp a new set of Alignment – shim as
reference rails in the required
machine and check:

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16 Operate the machine in If any parameters are
test mode and time the incorrect, adjust as
flashing speed, upset necessary.
speed and weld
periods.
17 Check each This should be not
transformer resistance. less than 1.0 Mega
Ohm when checked
with a 500 V mega
ohm meter.
If resistance is
incorrect, the
transformer must be
heated (dried) until
correct level is
reached.

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Monthly Maintenance
Perform the weekly procedures and also weld two sample rails for testing (Test welds are
recommended, but not mandatory).
Lubricate all crane points
Lubricate rear door hinges
Lubricate all roller guides and latches
Check condition of straps, hooks and tensioning mechanisms
Check ALL electrical connections
1 Crane Lube Lubricate ALL

Points Climbing
Irritant
Confined spaces
Obstructions
Sharp edges
2 Door hinges Lubricate rear door
hinges, all around. Obstructions
Sharp edges
Pinch Points
3 Roller Lubricate roller guides
guides and and latches (ALL) Hot surfaces
latches
OTHER HAZARDS
Confined spaces
Obstructions
Sharp edges
Pinch Points
4 Straps, Check condition of
hooks and straps, hooks and Confined spaces
tensioning tensioning Obstructions
mechanisms mechanisms. Sharp edges
Pinch Points

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Quarterly Maintenance
Main control Clean vent louvers and

panel vent filters, inside and out.
louvers and
filters Obstructions
Sharp edges DO NOT USE
Pinch Points DAMAGED
REPLACEMET
FILTER OR
ELEMENTS

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Semi-Annual Maintenance
This procedure should be carried out every 6 months and before starting work at a new site depending
on engine hours and flash butt welding unit’s previous production load.
Replace fuel filters on the genset.
Drain genset engine oil. Add the specified amount of to fill the oil pan DO NOT OVER FILL.
Check the SCA concentration level
Check the antifreeze concentration.
Do a cooling system pressure test. Repair or replace components as needed
Check engine ground connection. Ensure that good electrical contact is maintained.
Service batteries
Inspect the engine rubber mounts for deterioration and age hardening.
Check automatic belt tensioner tension and belts for wear
Change engine lubricating oil filter.
Clean genset engine fuel/water separator

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1 Genset Replace fuel filter (After initial 250 hours

engine fuel following
filter commissioning)
Flammable vapors Do not use damaged
Flammable liquid filters.
Use only approved
replacement parts
Diesel fuel disposal

2 Genset Drain genset engine oil Refer to
engine oil Add the specified manufacturer’s
amount of to fill the oil documentation for
Hot Oil
pan DO NOT OVER recommended for the
Hot surfaces
FILL. best engine durability
Check the oil level on at higher ambient
the dipstick. o the H temperature.
(high) mark
Lubricating oil
disposal
3 Supplement Check the SCA Use proper SCA
al Coolant concentration level coolant kit
Additive Check the antifreeze Use a mixture of 50-
(SCA) and concentration. percent water and 50-
Antifreeze Chemical exposure percent ethylene glycol
Concentrati or propylene glycol-
on based antifreeze to
protect the engine to -
32OC [-26OF] year-
around:
4 Cooling Pressure test cooling Use proper
System system replacement parts
Pressure Repair or replace Do not try to repair
Test components as needed Pinch Points damaged parts
Confined spaces
Obstructions
Sharp edges
5 Engine Check engine ground Repair and check
Ground connection. Ensure that before operations
Connection good electrical contact resume
High voltage
is maintained.

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6 Batteries Service batteries Refer to

manufacturer’s
documentation for
Flammable Gas & procedures and
vapors specifications.
Hydrogen gas
Acid
Hot surfaces
Sharp edges
7 Engine Inspect the rubber for Replace any broken or
Mounts deterioration and age lost bolts, cap screws,
hardening. or damaged rubber.
Confined spaces
Obstructions
Sharp edges
8 Automatic Check automatic belt Replace belts or
Belt tensioner tension and tensioner with
Tensioner belts for wear approved replacement
Pinch Points parts as needed
Confined spaces
Obstructions
Sharp edges
9 Engine Change engine DO NOT USE
lubricating lubricating oil filter. DAMAGED
oil and filter (element type) REPLACEMET
Hot oil
FILTER OR ELEMENT
Hot surfaces
Irritant
Confined spaces
Obstructions
Sharp edges

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10 Genset Clean fuel/water Do not use fuel/water

engine separator separator if damaged.
fuel/water Replace before
separator Flammable vapors operations continue
Flammable liquid Use only approved
replacement parts
Annual Maintenance
This procedure should be carried out every year.
1 Fuel Filter Change Fuel filter Do not use damaged

(Spin-On filters.
Type) Use only approved
Flammable vapors replacement parts
Flammable liquid
Spill Potential
Filter disposal
2 Hydraulic Drain Filter old hydraulic oil if
Reservoir Clean reused.
Refill
Hot coolant
Hydraulic oil disposal

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18-Month Maintenance
This procedure should be carried out every 18 months.
Drain, flush and refill the welder cooling system
Check the crankshaft vibration damper for evidence of fluid loss, dents, and wobble. Inspect the
vibration damper thickness for any deformation or raising of the damper cover plate.
Test the thermostats. Refer to manufacturer’s documentation for proper procedure.
Engine Valve Clearance, which includes the valves, injectors, and engine brakes (if equipped) must be
correctly adjusted for the engine to operate efficiently. Read manufacturer’s documentation before
attempting to perform this operation.
Replace crankshaft vibration damper.

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1 Welder Drain Filter old coolant if

Cooling Flush reused.
System Refill
Coolant disposal
2 Crankshaft Check the vibration Replace belts with
Vibration damper for evidence of approved replacement
Damper fluid loss, dents, and parts
wobble. Pinch Points
lnspect the vibration Confined spaces
damper thickness for Obstructions
any deformation or Sharp edges
raising of the damper
cover plate.
3 Thermostats Test Thermostats Refer to
manufacturer’s
documentation for
Hot oil
proper procedures and
Hot surfaces
specifications.
Irritant
Confined spaces
Obstructions
Sharp edges
4 Engine Read the entire Valves, injectors, and
Valve procedure for overhead engine brakes (if
Clearance adjustment before equipped) must be
attempting to perform Pinch points correctly adjusted for
this operation Confined spaces the engine to operate
Obstructions efficiently
Sharp edges
5 Crankshaft Replace damper Replace belts with
Vibration approved replacement
Damper parts
Pinch Points
Confined spaces
Obstructions
Sharp edges

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2 Years / Bi-Monthly
This procedure should be carried out every 2 years.
1 Engine Protect all electrical HAZARDS If steam is not

Steam components, openings High pressure spray, available, use a
Cleaning wiring from the full force soap, heat solvent to wash the
of the cleaner spray engine
nozzle
Spill Potential
Disposal of materials
blasted from engine.
2 Radiator Check all hoses for Replace belts with
Hoses cracks, cuts, or approved replacement
collapsing. parts
Confined spaces
Obstructions
Sharp edges
3 Fan Belts Replace fan belts and Replace belts with
and alternator belts as approved replacement
Alternator needed parts
Belts Pinch Points
Confined spaces
Obstructions
Sharp edges

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5 Years
This procedure should be carried out every 5 years.
1 Diesel fuel Drain Filter old diesel fuel if

tank Clean reused.
Refill
Flammable vapors
Flammable liquid

2 Fan Hub, Inspect the fan hub for Replace with
Belt Drive the following: approved replacement
Freedom of rotation parts
Cracks Pinch Points
Grease seal leakage. Confined spaces
Obstructions
Sharp edges

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Replace As Required
Replace fan belts and alternator belts with approved replacement parts.
Replace primary engine air cleaner filter element. Generally after initial 250 hours following
commissioning.
Replace secondary engine air cleaner filter element. Generally after initial 250 hours following
commissioning.
Replace genset engine fuel filter. Generally after initial 250 hours following commissioning.
Replace primary engine air cleaner filter element. Generally after initial 250 hours following
commissioning.
Replace secondary engine air cleaner filter element. Generally after initial 250 hours following
commissioning.
Replace air cleaner element when restriction shows vacuum of 625 mm (25 in.) H2O
During initial break-in, change the oil and filter for the first time after 100 hours of operation
(maximum).
Service intervals depend on sulfur content of the diesel fuel, oil pan capacity, and the oil and
filter used. (See DIESEL FUEL AND OIL FILTER SERVICE INTERVALS, in Fuels and
Lubricants, and Coolant section. Refer to engine manufacturer’s documentation. Replace fuel
filters when audible alarm sounds and trouble codes indicate plugged filter (low fuel pressure).
If no alarm sounds during a 12 month interval, replace fuel filters at that time, after every 500
hours of operation.
Replace crankshaft damper at 4500 hours or 60 months, whichever occurs first. Damper
cannot be repaired.

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1 Fan Belts Replace fan belts and Replace belts with

and alternator belts approved replacement
Alternator parts
Belts Pinch Points
Confined spaces
Obstructions
Sharp edges
2 Primary Replace filter element (After initial 250 hours
engine air following
cleaner commissioning)
element Dusts
Particulates
Filer element disposal
OTHER HAZARDS
Irritant
Confined spaces
Obstructions
Sharp edges
3 Secondary Replace filter element (After initial 250 hours
Hot oil
element
Hot surfaces
Irritant
Confined spaces
Obstructions
Sharp edges

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4 Genset Replace fuel filter (Initial break-in

engine fuel following
filter commissioning)
Diesel fuel
Flammable vapors
Filter disposal
4 Primary Replace filter element (Initial break-in
element Dust
Particulates
Filter disposal
5 Secondary Replace filter element (Initial break-in
element Dust
Particulates
Filter disposal
• Replace air cleaner element when restriction shows vacuum of 625 mm (25 in.) H2O
• During Break-in, change the oil and filter for the first time after 100 hours of operation (maximum).
• Service intervals depend on sulfur content of the diesel fuel, oil pan capacity, and the oil and filter
used. (See DIESEL FUEL AND OIL FILTER SERVICE INTERVALS, in Fuels and Lubricants, and
Coolant section. Refer to engine manufacturer’s documentation. Replace fuel filters when audible
alarm sounds and trouble codes indicate plugged filter (low fuel pressure). If no alarm sounds
during a 12 month interval, replace fuel filters at that time, after every 500 hours of operation.
• Replace crankshaft damper at 4500 hours or 60 months, whichever occurs first. Damper cannot be
repaired.

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CHECK LISTS
System Pre Start -Up Check List
CHECK POINT DAILY WEEKLY

Check hydraulic oil level *
Check water levels in refrigerant cooler (if so equipped) *
Check all hoses for signs of leaks *
Check fire extinguishers are fully charged *
Ensure manuals and spares are available *
Ensure welder “Firebox” surfaces are clean and free from
weld spatter.
Ensure welder is coated with Protex® or equal *
Check welder spark flaps for holes or tears. Ensure
attachments are secure. *
Check welder suspension *
Check welding area is clean and unobstructed *
Ensure appropriate data storage medias are available *
Ensure all guards are in place and secure *
Perform a visual walk around of welder unit *

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System Post Start Check List

When system is on line perform walk around *
Check for leaks, ensure NO LEAKS *
Check refrigeration pressure *
Check hydraulic pressures *
Check weld management system is in READY mode *
Check hydraulic oil filter indicator *
Exercise welding head before welding *
Run test weld (OPTIONAL)
Shut down system from each shut down position *
Check grease points on welder *
Check electrodes for cleanliness *
Check shear and linkage *
Change shear AS REQUIRED AS REQUIRED

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Shut Down

Air clean welder *
Remove ALL weld spatter
Check electrodes and inserts for damage and wear.
Repair or replace as needed.
Inspect spark flaps and guards. Repair or replace as
needed
Clean welder and coat with Protex or equal *
Check hoses and connections. ENSURE NO LEAKS *
ORDER PARTS AND SUPPLIES AS REQUIRED AS REQUIRED

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NOTES

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Section 7
TROUBLESHOOTING

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NOTES

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TROUBLESHOOTING GUIDE FOR WELDER AND CONTROLS
TROUBLE POSSIBLE CAUSES REMEDY

Clamps cylinders move - air trapped in hydraulic - bleed system at welder
erratically or slowly system manifold
- cold weather/cold oil - warm up oil
- insufficient pressure in - adjust compensator

system setting
- check relief valve and
reset as required
- low oil level in tank - fill tank
- solenoid valve malfunction - check valve operation

and check wiring; replace
or correct
- quick disconnect not - open quick disconnect
correctly connected and reconnect
Clamp cylinders do not - switch in AUTO position - move to set up
move
- quick disconnects - open quick disconnects
incorrectly installed and re-connect
- clamp switch in OFF - move switch to clamp or
position unclamp position
Upset cylinders move - air trapped in hydraulic - bleed system at welder
erratically during setup system manifold
- quick disconnect not - open quick disconnect
correctly connected and reconnect
- circulating valves open (if - close valve
fitted)
- insufficient pressure in - adjust compensator
system setting
- check relief valve and
reset and reset as required

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- cold weather/cold oil - warm up oil

- solenoid valve malfunction - check valve operation
and check wiring; replace
or correct
Clamp cylinders do not - piston or gland leaks - check flow from gland; if
clamp evenly excessive replace gland
packing and piston rings
- valve leakage - check valve operation;
replace as required
- solenoid not switching - check wiring to solenoid
- replace solenoid
Upset cylinder advance is - air trapped in hydraulic - bleed system at welder
erratic during weld cycle system manifold
- speed control valve - reset valve controls
malfunctioning - ensure control card is
correctly seated in holder
- check electrical
connections to valve
- bleed air from valve vent
screw
- pump compensator - check wiring to valve
malfunctioning - ensure control card is
seated
- relief valve lifting - check and reset
- excessive tension in rail - release more spikes /
causing system to relieve at clips
maximum pressure
- piston/gland leakage - check leakage; change
packings/rings as required
- upset rods and axle not - add grease
greased
- upset rod(s) - check rods for trueness;
damaged/scored replace as required
Uneven extension of upset - piston stroke incorrect - check stroke; adjust to
cylinders give identical extension on
each piston rod
- piston / gland leakage - check leakage; change
packings and rings as
required
- upset rod(s) damaged / check rods for trueness;
scored replace as required

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- rod clamp loose allowing - tighten fixing screws
movement
Uneven clamping - different rail sections - do not weld; only similar
sections permitted for
welding
- one rail section worn; - add shims to worn rail to
allows alignment block to correct alignment
position rail incorrectly
-rail not fully in clamps - release clamps and
reposition
- clamps on one side worn - check alignment and shim
and loose clamps as required
Rail slips during weld - clamps incorrectly set check alignment and shim
clamps as required
NOTE: If welder slips, - incorrect hydraulic - check pump and set
copper will be left on rail and pressure compensator to correct
must be removed by pressure
grinding before re-clamping. - rail surfaces incorrectly - open clamps and regrind
prepared before clamping web surfaces
Upset cylinders do not fully - cylinder rod stroke - adjust rod stroke using
extend adjustment is incorrect special tools
- build-up of weld - extend cylinder and clean
slag prevents full off slag and weld splatter
-stroke
shear device not fully - remove device; clean
seated on pivot pins splatter from welder faces;
reset shear on pivot pins
Shear does not remove - insufficient pressure in - check pump; reset
weld flash hydraulic system compensator to correct
pressure
- cutting edge worn - remove shear; regrind
cutting edge
- rail head height incorrect - make sure rail alignment
is correct before
commencing welds
- shear is incorrectly - adjust position using
positioned on rail eccentric cam to give
uniform clearance around
the rail
Required welding voltage - output voltage too low - adjust autotransformer taps
not available
Weld duration incorrect - timers incorrect - check stage timers and
adjust as required

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Weld not completed - rail incorrectly positioned in - cut out weld material and
machine; rail usage restart
prevents full stroke from
being used
Flash will not start - rail ends not cleaned - open machine; clean rail
correctly ends; ensure ends are
clear of grease or rust
- poor contact between - remove rail; clean
electrodes and rail surface; clean electrode
faces
- incorrect voltage applied - check setting; increase
voltage as required
- rail approach speed - check flow control valve
excessive and speed reference;
adjust as required
- system not in AUTO mode - switch to AUTO
- system still in SET UP - switch to RUN
mode
- welding voltage not - check WESPAC board
available lights for status (note
status). Switch off power
to panel and reset board.
Flashing is interrupted in - rail approach speed - check flow control valve
AUTO mode (HIGH current) marginally too high and speed reference;
adjust as required
- insufficient pressure to pull - increase pressure or
rails together release more rail clamp
- incorrect voltage applied - check voltage setting;
adjust as required
- incorrect stage timer - check timer setting; adjust
setting or malfunction as required
- rail/electrode contact poor - check quality of grinding
and ensure bare metal
contact
- machine impedance high - check secondary circuits
Flashing is interrupted in - SCR’s not firing - check WESCON board
AUTO mode (no power) - power supply incoming
- check connections to
board
- check and note condition
of board indicator light
(review with WESCON
board trouble shooting)

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PARTS ORDERING INFORMATION SHEET
Fill out a copy of this form for each unit purchased.
Have this information at hand when calling for service or parts. This will help us help you to service your
purchase efficiently and quickly.
PRODUCT TYPE:
(Example: Container Welder, Welder Head, Mobile Welder, etc.)
UNIT MODEL NUMBER:

(Example: H-650, H1000, Container Welder, or refer to contract)
UNIT SERIAL NUMBER:

(Check Data Plate or Decal on Machine or Container)
GENERAL CONTACT INFORMATION

Holland Company L.P.
1000 Holland Drive
Crete, Illinois 60417-2120
Phone: (708) 672-2300
FAX: (708)-672-0119
Web Site: www.hollandco.com
DIRECTOR OF INTERNATIONAL SALES

Shekhar Taneja
Phone: (708) 672-2323
Cell: (708) 217-6771
FAX: (708)-672-0119
Email: staneja@hollandco.com
SR. APPLICATION ENGINEER

Igor Mosendz
Crete Illinois, USA
Phone: ++1-708-672-2355
Cell: (815) 409-0048
Email: imosendz@hollandco.com


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Holland L.

SERVO CONTROLLED FLASH BUTT WELDING

OPERATION AND MAINTENANCE MANUAL

Holland Equipment Division's Quality Management

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DRAWINGS AND ILLUSTRATIONS

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SECTION 7 ........................................................................................................................................................................ 119

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DRAWINGS AND ILLUSTRATIONS

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EQUIPMENT WARRANTY POLICY

3. Normal wear and tear is specifically excluded from this warranty.

10. The validity of this warranty is subject to the following conditions:

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Safety (Continued) Hydraulic System Safety

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Remove all flammable materials from the work zone.

Fire extinguishers must be located within easy access during operations.

Do not open welder covers during welding process.

Do not stand on wet ties when operating welding machine.

Keep machine clean at all times.

Remove weld splatter after each operation.

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Remove weld spatter after each operation.

DO NOT CHANGE MACHINE SETTINGS WITHOUT QUALIFIED STAFF INSTRUCTION

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Refer to manual or Pollutant,

Warning Hot (Generic)

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Struck By Caught Between

Inhalation Hazard No Leaks

Entangled Irritant (skin, tissues,

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Lock Out and Tag Out

Burn Hazard Fire Hazard

Lockout and Tagout ZERO ENERGY

No Leaks Light Oil Lube Point

Clean with: Coolant Water Fill Point

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Hand Auto, Automatic

Rail Clamp, Clamp Rail Clamp, Unclamp

Rail Clamp, Off Welding Flash (Eye

Shear Close (Selection,

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Platen Forward, Slow,

Platen Reverse, Slow

Setup, (Selection, Weld Cycle Stop,

Weld Cycle Start,

Clamp Release, Right,

Clamp Release, Left,

Recycle, Dispose of On, (Selection, Setting)