ERICO CADWELD Propulsion Rail - Web Bond - Manual (Page 4)

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! 7. Carefully open the mold cover and break up the slag in the crucible
using the blade of the mold cleaning tool. Dump the slag from the
crucible and remove slag from the taphole using the curved end of
the mold cleaner. Dump slag in the ballast, not onto the ties.
8. Check the molds for breakage or residual slag before proceeding
with the next weld.
V. INSTRUCTIONS FOR FIELD-MADE TERMINALS
1. Strip insulated conductor a minimum of sleeve length
plus 1 inch (25 mm).
2. Cable and sleeve must be clean, bright and dry.
3. Insert conductor through sleeve so strand ends protrude
approximately 0.02–0.04 inches (0.5 –1.0 mm). See Figure 15.
4. Place sleeved conductor into designated hammer die, locate
fl are of sleeve against side of die.
5. Close die, use hammer or press to form terminal (use care to
maintain sleeve and conductor ends in position).
6. Top of die must be tight against die body to properly form
terminal.
7. Mark terminal using saw cut in hammer die when provided.
Trim bond at mark. See Figure 16.
CAUTION: Install only the specifi ed welding material in
the mold crucible. Use only the welding material size that is
specifi ed on the mold. ERICO brand of welding material (F80) is
formulated specifi cally for use with rail steels; it is packaged in
a blue tube with a yellow cap. Dump all of the welding material
into the crucible, then carefully tap the tube on a hard surface
to loosen the starting material from the bottom of the tube and
distribute half on top of the welding material, close the mold
cover, and pour the remainder in the opening of the mold cover.
See Figure 13. Failure to comply may result in diffi culty getting
the reaction started and/or an unacceptable weld.
IPRPW_C R1297IS09WWEN PUR1113
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FIGURE 13
CADWELD ® Propulsion Rail - Web Bond
Refer to the mold tag for applicable instruction sheets. IPRPW_C
FIGURE 14
5. Place welder against rail web. Hold fi rmly or clamp if using
T20 style. Clamp is adjustable for rail sizes. Check that mold
face
fi ts against rail and bond terminal is held against rail.
NOTE: Clamp on T20 style can be swung out of way to make
hand held welder. See Figure 14. Maintain correct positioning
of the hand held welder at the neutral axis of the rail web
(refer to “WARNING: Correctly positioning the mold against
the rail web...” on page 3).
CAUTION: Avoid direct eye contact with the “fl ash” of light
from the ignition of the starting material.
6. Position yourself upwind of the mold, on the fi eld side of the
rail. Place the tip of the fl int igniter at the cover opening and
ignite. Remove the igniter quickly to prevent fouling.
CAUTION: Allow 15 seconds for mold cooling after the
reaction. This will permit the molten metal to solidify. Then
carefully disengage the welder device and pull the mold straight
back from the rail. Failure to observe this may result in mold
damage and its premature scrapping. Molds can generally be
re-used up to 50 times.
Note: If you have any questions or require further instructions,
or would like training, contact ERICO at 1-800-447-7245.
FIGURE 15
FIGURE 16
Positioning Sleeve
Disk
Welding Material
1/2 Starting Material
Crucible Cover
1/2 Starting Material
0.02 – 0.04 inches (0.5 –1.0 mm)
Forming – Using Hammer-Die