HOLLAND H1000 WELDER WITH 160 T PULLER

OPERATING SEQUENCE
(AS EXAMPLE FOR DE-STRESSING OF EXISTING TRACK WITH
WELDED IN PLUG)
1. ARRIVE TO DE-STRESSING LOCATION IN TRACK

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 HOLLAND H1000 WELDER WITH 160 T PULLER
OPERTING SEQUENCE
2. HAVE INFORMATION ON AREA NT
3. MEASURE ACTUAL RAIL TEMPERATURE T. INSURE
T IS BELOW OR EQUAL TO NT TO PROCEED WITH DE-
STRESSING. ENSURE THAT WEATHER IS ADEQUATE
TO KEEP T ≤ NT FOR ABOUT ONE HOUR
4. ENSURE DE-STRESSING LOCATION ALLOWS TO
WELD IN PLUG ABOUT 6 M LONG AND DISTANCE
BETWEEN WELDS IN TRACK AFTER DESTRESSING
WILL BE AS MINIMUM 6 M (OR AS MINIMUM ALLOWED
BY IN-COUNTRY SPECIFICATION)
5. ENSURE PLUG ABOUT 6.0 (+) M IS DELIVERED TO
LOCATION.
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 HOLLAND H1000 WELDER WITH 160 T PULLER
OPERTING SEQUENCE
6. ENSURE PLUG RAIL HEIGHT DOES NOT DIFFER
FROM TRACK RAIL HEIGHT MORE THAN 2 MM
7. UNCLIP 500 M OF TRACK IN DIRECTION FROM
WELDER.
8. FLAME CUT RAILS IN FIRST PLUG WELD LOCATION.
NOTE IF RAILS MOVED APART OR TOGETHER AFTER
FLAME CUT TO REPORT ORIGINAL TRACK CONDITION
TO RAILWAY AUTHORITIES.
9. CUT OUT FLAMED TRACK RAIL END WITH RAIL SAW
– MINIMUM 25 MM FROM FLAME CUT SURFACE.

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 HOLLAND H1000 WELDER WITH 160 T PULLER
OPERTING SEQUENCE
10. MOVE UNCLAMPED TRACK ASIDE TO LOCATE
PLUG
11. LOCATE PLUG IN TRACK TO MAKE FIRST WELD

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 HOLLAND H1000 WELDER WITH 160 T PULLER
OPERTING SEQUENCE

10. LOWER WELDER WITH PULLER ON TRACK IN

LOCATION OF FIRST WELD
11. DISCONNECT PULLER FROM WELDER AND MOVE
WELDER ASIDE
12. GRIND RAILS IN CLAMPING AREA TO BARE METAL
13. CLAMP RAILS IN PULLER
14. PULL RAILS TOGETHER TO GAP ABOUT 2 MM
15. PRE-ALIGN RAILS BY PULLER
16. COMPLETE FIRST WELD. WELD RECORDING WILL
START AUTOMATICALLY WITH WELD START
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HOLLAND H1000 WELDER WITH 160 T PULLER
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 HOLLAND H1000 WELDER WITH 160 T PULLER
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17. LOAD TENSION WELDING PARAMETERS TO PLC
18. TYPE OPERATOR NAME

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 HOLLAND H1000 WELDER WITH 160 T PULLER
OPERTING SEQUENCE
19. TYPE LOCATION – GEOGRAPHICAL, TRACK KM,
CHAINAGE, ETC.

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 HOLLAND H1000 WELDER WITH 160 T PULLER
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20. SELECT RAIL SIZE – QUANTITY IS UNRESTRICTED

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 HOLLAND H1000 WELDER WITH 160 T PULLER
OPERTING SEQUENCE
21. INPUT NT FOR THE AREA

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 HOLLAND H1000 WELDER WITH 160 T PULLER
OPERTING SEQUENCE
22. INPUT ACTUAL RAILS T

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 HOLLAND H1000 WELDER WITH 160 T PULLER
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23. INPUT LENGTH OF UNCLIPPED RAILS

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 HOLLAND H1000 WELDER WITH 160 T PULLER
OPERTING SEQUENCE
24. CLICK “OK” AND COMPUTER WILL SHOW READY
TO WELD MONITOR

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 HOLLAND H1000 WELDER WITH 160 T PULLER
OPERTING SEQUENCE
25. RELEASE PULLER FROM RAILS AND LIFT
WELDER/PULLER TO TRAVEL POSITION
26. CLIP WELDED PLUG TO SLIPPERS
27. MOVE OTHER SIDE OF TRACK TO PLUG

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 HOLLAND H1000 WELDER WITH 160 T PULLER
OPERTING SEQUENCE
28. CUT LONG RAIL END TO PROVIDE 18 MM GAP
BETWEEN RAILS IN WELD AREA
29. MOVE RAIL AFTER CUT TO PLUG END

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 HOLLAND H1000 WELDER WITH 160 T PULLER
OPERTING SEQUENCE
30. LOCATE WELDER AND PULLER OVER SECOND
WELD
31. DISCONNECT WELDER FROM PULLER AND MOVE
WELDER ASIDE
32. CLAMP RAILS IN PULLER. PULL RAILS TOGETHER
SEVERAL TIMES AND RELEASE TO STRETCH
UNCLIPPED RAIL SECTION
33. MEASURE IF GAP BETWEEN RAILS IS STILL 18 MM.
CORRECT (CUT RAIL END) IF REQUIRED.
34. PUSH “RECORD” BUTTON ON PULLER CONTROL
PANEL.
35. PULL RAILS TOGETHER TO 1…2 MM GAP
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 HOLLAND H1000 WELDER WITH 160 T PULLER
OPERTING SEQUENCE
36. PREALIGN RAILS BY PULLER
37. LOWER WELDER ON RAILS AND CLAMP RAILS IN
WELDING HEAD
38. COMPLETE WELD
39. UNCLAMP WELDER FROM COMPLETED WELD,
LIFT AND MOVE ASIDE
40. KEEP RAILS CLAMPED IN PULLER FOR ABOUT 8
MINUTES TILL WELD TEMPERATURE WILL BE BELOW
700ºF (370ºC)
41. LOWER RAILS ON SLEEPERS AND UNCLAMP
PULLER
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 HOLLAND H1000 WELDER WITH 160 T PULLER
OPERTING SEQUENCE
42. GENERATE WELDING CHART FROM UNIT PC ON
COMPLETED DE-STRESSING WELD

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FLASH BUTT WELDING EQUIPMENT

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