Cembre LD-1P-ECO Operation And Maintenance Manual

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15 M 067 E

ENGLISH

Cerﬁed Quality

Management System

TYPE

Cerﬁed Environmental

Management System

Cerﬁed Occupaonal

Health & Safety

Management System

RAIL DRILL

LD-1P-ECO

OPERATION AND MAINTENANCE

MANUAL

WARNINGS

– Before using the drill, carefully read the instructions contained in this manual. SAVE THESE INSTRUCTIONS: this manual contains important safety and operating instructions for the drill.

– STOP THE ENGINE when servicing the drill: before removing the broach cutters, spiral bits, positioning templates etc.

– During operation keep hands away from the danger zone.

– Always wear protective glasses and work gloves.

– Avoid wearing clothes which may present a risk to personal safety.

LD-1PN-ECO basic drill

LD-1P-ECO

basic drill complete with railweb clamping device

1. GENERAL CHARACTERISTICS

LD-1PN-ECO

Drilling capacity (*):

Speed without load:

Weight:

Weight with DBG-F2:

Gear sump

Recommended oil:

Combustion engine:

Type: Model: Displacement: Power (SAE J1349): Fuel tank capacity Clutch

Start: Ignition: Spark plug: Fuel: Fuel consumption: Emissions:

Ø 7 ÷ 40 mm

270 rpm

15,7 kg

18,9 kg

SHELL SPIRAX S4 TXM or

MOBIL SUPERMULTIGRADE 10-30-SAE or equivalents

2-stroke, horizontal shaft, single cylinder

KAWASAKI TJ45E

45,4 cm

1,4 kW (1,9 HP) / 7500 rpm

0,9 litres

centrifugal with automatic intervention

by rope pull

solid state ignition (none breaker)

NGK BPMR7A o

r equivalents

2% (1:50) oil/petrol mixture (see § 8)

470 g/kW.hr / 350 g/hp.hr

according to "Phase 2"

European Directives 97/68/EC, 2001/63/EC and 2002/88/EC

Acoustic Noise (Directive 2006/42/EC, annexe 1, point 1.7.4.2 letter u)

– The weighted continuous acoustic pressure level equivalent A at the work place L – The maximum value of the weighted acoustic displacement pressure C at the work place L – The acoustic power level emitted by the machine L

is equal to .............................................................................................................................107,6 dB (A)

is equal to ........................................................................................ 99,5 dB (A)

is equal to ...............................................................116,3 dB (C)

pCPeak

Risks due to vibration (Directive 2006/42/EC, annexe 1, point 2.2.1.1)

Tests carried out in compliance with the indications contained in UNI ENV 25349 and UNI EN 28662 part 1 mally found, certify that the weighted root mean square in frequency of the acceleration

) with broach cutters on thicknesses up to 50 mm

(

with special spiral bits on thicknesses up to 45 mm

the upper limbs are exposed is 4,36 m/sec

Standards and under operating conditions much more severe than those nor-

max.

2. ACCESSORIES SUPPLIED WITH THE DRILL

2.1) Guide bits for controlling the cooling system:

for broach cutters suitable for drilling thicknesses of up to 25 mm – 1 pc PP 1, diameter 7 mm – 1 pc PP 2, diameter 8 mm

for broach cutters suitable for drilling thicknesses of up to 50 mm – 1 pc PPL 1, diameter 7 mm – 1 pc PPL 2, diameter 8 mm

2.2) Spacer, type DPE, for controlling the cooling system with special spiral bits, diam. 7 ÷ 27,5 mm.

2.3) Adaptor, type ARE, for external cooling, to be used with the SR5000 cooling unit.

2.4) Grub screw, M8x10 – 4 pcs for clamping cutters or bits on the spindle shaft.

2.5) Socket head cap screws, M6x16

– 4 pcs for securing positioning templates to the front plate.

2.6) Socket head cap screws, M6x25

– 4 pcs for securing special positioning templates to the front plate.

2.7) Range of tools:

– 1 pc 5 mm allen key – 1 pc 6 mm allen key – 1 pc 4 mm allen key with handle – 1 pc sparkle plug key – 1 pc brush

2.8) Measure for mixture preparation.

2.9) 100 ml oil for the gear reduction.

(Accessories 2.1 to 2.9 are included in the “Kit of accessories”code 6001356).

2.10) Type SR5000 cooling unit.

3. ACCESSORIES TO BE ORDERED SEPARATELY

3.1) DBG-F2 device (*) with moving arm for clamping the drill to the

rail web and track ﬁttings, complete with the following end pieces:

– TDB 1: for switch blades and compound frogs. – TDB 3: for repairing (adjusting) existing holes on rails for subse-

quent application of electrical connections and for additional special applications. – TDB 6: standard end piece for rails and stock rails.

(*) Supplied with drilling machine ref. LD-1P-ECO

3.2) DBG-LF2 device with moving arm complete with TDB 7 end piece for clamping the drill to girder rails and for additional special applications.

TDB 1

TDB 6

TDB 3

3.3) DBSN device for clamping the drill to ﬂange

TDB 6

TDB 3

rails, for use in conjunction with the MPAF tem-

TDB 7

plates. Using this device the rail drill can remain clamped in the drilling position even when trains pass over it.

3.2) “VAL P24” plastic carrying case for storing the drill complete with the DBG-F2 device and

accessories. Also available VAL P24-CS plastic carrying case with folding handle and wheels.

3.2.1) “VAL LD-L” metal case for storing the drill complete with the DBG-LF2 device, and VAL MPA tool case.

VAL P24-CS

VAL LD-L

3.5) Templates for positioning the drill on the rails and stock rails to enable drilling to be carried out according to the provisions of railway boards standards: e.g.: – MPAF UIC54 on DRILLING AXIS of 54E1 rail – MPAF UIC60 on DRILLING AXIS of 60E1 rail

• Note: Contact Cembre for selection of speciﬁc application

accessories (e.g.: positioning templates for other rail proﬁles).

3.6) MPAU universal positioning template suitable both for repairing existing holes on various ﬁttings, and for drilling disused rails.

3.7) SPA positioning plates for drilling rail heads with a centre-to-centre distance es- tablished in the Railway boards standards,

without the need for marking out; for use in conjunction with the MPAF... positioning templates.

3.8) MRF clamp to be applied as a reference to the head of rails for use, in conjunction with the SPA ... connecting plates, for in-line drilling of the rail heads, with established centre-to-centre distance.

3.9) VAL MPA metal box

suitable for accommodating accessories 3.5 - 3.11.

3.10) Broach cutters

BROACH CUTTERS FOR RAILS IN STEEL QUALITY 700-900-1100 (UIC 860.0)

13,5

17,5

27,5

SHORT RANGE

Broach cutter Guide bit

CY130 CY135

Ref. PP 1

CY160 CY170 CY175 CY180 CY190 CY200 CY210 CY220 CY230 CY240 CY250 CY260

Ref. PP 2

CY270 CY275 CY280 CY290 CY300 CY310 CY320 CY330

MAX DRILLING THICKNESS

25 mm

LONG RANGE (L max = 88mm)

Broach cutter Guide bit

CY140L CY160L

Ref. PPL 1

CY170L

CY180L CY190L CY200L CY210L CY220L CY230L CY240L CY250L CY260L

Ref. PPL 2

CY270L

CY280L CY290L CY300L

CY320L CY330L

MAX DRILLING THICKNESS

50 mm

Contact Cembre for other types of broach cutters.

Broach cutter resharpening must be carried out in compliance with appropriate methods of operation which provide the best result.

3.11) Spiral bits

APED...

FIG. 1

APE...

L max

L max mm

Adaptor

1,6

ref.

APED 135/165

FIG. 2

SPECIAL SPIRAL BITS FOR RAILS IN STEEL QUALITY 700 - 900 - 1100 (UIC 860.0)

Spiral Bit

Figure

7,1

8,5

9,5

10 11 12 13

13,5

– Special spiral bits in the PE range allow automatic cooling by means of the SR5000 unit supplied with the drilling machine. – All spiral bits in the PE range allow drilling of thicknesses up to 45 mm.

ref.

(*)

PE 70 PE 71 PE 80 PE 85 PE 90 PE 95 PE 100 PE 110 PE 120 PE 130AR PE 135AR

L max mm

76 72

APED 70

1,2

APED 80

1,4

APE 90 APE 95 APE 100 APE 110 APE 120

1,6

APED 130 APED 135/165

Adaptor

ref.

Figure

14 16 17

17,5

18 19 21 22 24

27,5

Spiral Bit

ref.

(*)

PE 140 PE 160 PE 170AR PE 175 PE 180 PE 190AR PE 210AR PE 220 PE 240AR PE 275AR

(*) PE... AR: special high quality spiral bit.

The drilling bits indicated in the tables guarantee optimum results. For bits of other types, check the dimensional compatibility (particularly the size of the attachment and the length).

3.12) LR2 BIODEGRADABLE LUBROCOOLANT

3 litre container to be used in a 5-10 % solution, for optimum operation of broach cutters and

spiral bits.

3.13 LR3 ANTIFREEZE CONCENTRATE

3 litre added to the lubrocoolant mixture in the right concentration will

maintain the lubrocoolant mixture ﬂuid in negative temperature conditions.

4. COOLANT UNIT TYPE SR5000

The type SR5000 coolant unit consists of a tank complete with tube and maximum pressure valve (01) ﬁtted with a pump device for pressurisation, which must be connected to the attachment (35) on the drill by means of its quick-coupling (03).

The delivery and shut-oﬀ of the lubrocoolant are controlled automatically when drilling with a broach cutter from the position of the guide bit; when drilling with a spiral bit, delivery and shut-oﬀ of the ﬂuid must be eﬀected manually by operating the tap (02). The use of the

lubrocoolant supplied by Cembre, in the recommended concentrations, guarantees optimum use of the drilling tools.

Consumption of the lubrocoolant depends both on the variable degree of opening of the tap (02) and the inner pressure of the tank: it is therefore advisable to open the tap a little when the tank is at maximum pressure, while it must be fully opened when the pressure in the tank is low.

When using the coolant system, pay careful attention to the instructions on the tank label.

Warning:

• When the tank is not under pressure, check that the bush on the maximum pressure valve

is screwed right down.

• To fill tank with lubrocoolant, turn handle anticlockwise approximately 2 turns to release

handle locking mechanism. Remove handle/piston assembly from tank.

Detail of the max pressure valve

17 – Vent valve 35 – Attachment valve 01 – Tank complete with tube and max. pressure valve 02 – Tap 03 – Quick-coupling

FIG. 3 – COOLING UNIT

• The rail drill is equipped with the cooling attachment valve (35) and a vent valve (17) which

are located as shown (Fig. 3). If under certain operating circumstances they need to be interchanged, proceed as follows:

– With a 17 mm hexagonal key, unscrew the vent valve from its seat. – Using the 4 mm Allen key provided with the drill, remove the attachment cooling valve from its seat and ﬁt into the vent valve seat. – Fit the vent valve into the removed coolant valve seat.

• When temperatures fall below 0° C the

lubrocoolant may freeze which could cause damage to the seals contained in the drill cooling system. It is therefore advisable, when storing the drilling machine, to empty the lubrocoolant system completely. Proceed as follows (Fig. 4):

– Disconnect the quick coupling (03) from the coolant attachment (35) on the drilling machine. – Tilt the machine so that the coolant attachment is at its lowest point - allowing for natural drainage. – Operate the advance lever (36) to advance and retract the drilling spindle. – Gently shake the machine to establish expulsion of all ﬂuid.

FIG. 4

4.1) ARE adapter

For use with the SR5000 cooling unit. The ARE adapter is inserted in the quick-coupling of the tank tube (Ref. to Fig. 5). May be used to provide manual external cooling when cutters are

used to enlarge existing holes or when using spiral bits not designed for automatic cooling.

If necessary, the ARE adapter can also be used to clean various parts of the drill, by means of the lubrocoolant pressure jet, e.g. parts such as the tool clamping seat in the spindle shaft, seats for the jig ﬁxing screws, etc.

ARE adapter

FIG. 5 – ARE ADAPTER

5. SPINDLE ADVANCE LEVER

The spindle is advanced by moving the lever (36) (See Fig. 6a). The lever is ﬁtted with a release pawl (39) which, when pressed, renders it independent of the hub and hence the spindle; the operator can therefore easily vary the angular position of the lever without movement of the spindle (Fig. 6b).

FIG. 6

6b - With the release pawl (39) pressed, the lever is released from its hub and can repeat the previous travel without the spindle moving.

5.1) Adjustment of the advance lever

The movement of the lever must never be loose. For adjustment proceed to tighten it by loading the cup springs by means of the associated self-locking nut, after removing the protective cap (see Fig. 7).

6a - Moving the lever (36) towards the operator; corresponding advance of the spindle.

6c - With the hub released, moving the lever towards the operator causes a corresponding advance of the spindle.

FIG. 7

6. PREPARING THE DRILL

STOP THE ENGINE when servicing the drill: before removing the broach

cutters, spiral bits, positioning templates etc.

6.1) Assembling broach cutters (Ref. to Figs. 8-11).

6.1.1) Insert the guide bit in the cutter from the side of the spigot.

6.1.2) Using the lever (36), position the spindle shaft (07) so that both grub screws (18) become

accessible and suﬃcient space is provided to insert the cutter; if necessary rotate the spindle shaft manually and suﬃciently by inserting the 4 mm allen key in the appropriate intermediate gear housing (33) in the crankcase of the drill (see Fig. 11).

6.1.3) Insert the cutter in the spindle shaft so that the two engaging dogs on the cutter spigot line up with the grub screws (18).

6.1.4) Clamp the cutter by fully tightening the grub screws using the 4 mm allen key.

6.1.5) Check that the guide bit slides freely by applying slight pressure on it.

Engaging dogs

Short type broach cutter Maximum drilling thickness: 25 mm

Guide bit PP...

Guide bit PPL ...

Long type broach cutter Maximum drilling thickness: 50 mm

FIG. 8 – ASSEMBLING BROACH CUTTERS

6.2) Assembling special spiral bits (Ref. to Figs. 9 - 11)

6.2.1) Using the advance lever, position the spindle shaft so that both grub screws become

accessible and suﬃcient space is provided to insert the spiral bit; if necessary rotate the spindle shaft manually and suﬃciently by inserting the 4 mm male hexagon key in the appropriate intermediate gear housing (33) in the crank-case of the drill (see Fig. 11).

6.2.2) Insert into the spindle shaft, the DPE spacer required to activate the cooling device. If necessary to use APE... adapter (see pag. 7) the bit must ﬁrst be ﬁtted in the corresponding APE adapter and locked with the appropriate grub screw. Then the DPE spacer may be inserted.

Note: Adapters type APED… do not require use of DPE spacer.

6.2.3) Insert the bit-spacer unit in the spindle shaft so that the two engaging dogs on the bit spigot line up with the grub screws. Press the bit-spacer unit home against the inner

seat of the spindle: this will enable the DPE spacer to open the cooling circuit (see Fig. 10).

6.2.4) Clamp the bit by fully tightening the two grub screws (18) using the 4 mm male allen

key.

DPE *

DPE

* use only for APE..., not required for APED...

FIG. 9 – ASSEMBLING SPIRAL BITS

Bits PE ... (e.g. PE 95)

Bits PE ... (e.g. PE 190)

FIG.10 – ASSEMBLING BIT-SPACER UNIT

FIG. 11 – MANUAL SPINDLE ROTATION

7. DRILL TYPE LD-1P-ECO

The reference LD-1P-ECO relates to the basic drill complete with the moving arm device type DBG-F2 for clamping it to the rail web and the track ﬁttings (Ref. to Fig. 12).

The DBG-F2 device consists of: – Clamping unit – Type TDB 1 termination – Type TDB 3 termination – Type TDB 6 termination – Socket head cap screws M 8x25 (2 pcs) – Spring washers (4 pcs) – Reference pin

FIG. 12 – DRILL LD-1P-ECO

M 8x25 screws

and spring washers

reference

TDB 3

TDB 6

TDB 1

7.1) Assemble of the terminations of the DBG-F2 device with moving arm for clamping the drill to the rail web and track ﬁttings.

The terminations TDB 1, TDB 6 and TDB 3 of the DBG-F2 device, with moving arm, have been designed for adaptation to the diﬀerent operating conditions on rails and track ﬁttings; their assembly is shown in Fig. 13.

• When assembling the type TDB 3 termination remember that the positioning pawl must be down in relation to the bolt.

• When disassembling the TDB 6 termination, please bear in mind that after removing the pivot, it is necessary to slide the complete assembly away downwards, being careful not to act on the holding plate.

• Over-advancing the spindle after drilling must be avoided using the TDB 1 and TDB3 terminations.

holding plate

Termination TDB 1 for switch blades

and compound frogs

Termination TDB 3 for enlarging existing holes on rails inherent in the application of electrical connections and for additional special applications.

Termination TDB 6 for rails and stock rails

Seats to be used for special applications.

positioning pawl pointing downwards

FIG.13 – ASSEMBLY OF THE TERMINATIONS

7.2) Assembly of the DBG-F2 clamping device on the drill

The DBG-F2 clamping device is ﬁtted to the front plate of the drill, centred by means of the reference pin supplied and secured with the two socket head cap screws M8x25 (35) also supplied. The assembly is illustrated in Fig. 14.

DBG-F2 Clamp

FIG. 14 – ASSEMBLY OF THE “DBG-F2” CLAMP

Drilling machine front plate

7.3) Assembly of the positioning templates (Ref. to Fig. 15)

7.3.1) The type MPAF.. and MPAU positioning templates are secured to the front plate (04) of

the drill by means of the two socket head cap screws M 6x16 supplied.

reference pin

FIG. 15 – ASSEMBLY OF THE POSITIONING TEMPLATES

MPAU

screws M6x16

MPAF...

7.4) Clamping to the rail web (Ref. to Fig. 16)

The drill has a rapid rail engagement/release mechanism and specially shaped positioning templates for each rail type which facilitate precise and certain location of the part to be drilled. To fully exploit the special features of the engagement device, we recommend calibrating it to the rail type to be drilled as follows:

7.4.1) Withdraw the spindle shaft (07) completely by means of the lever (36).

7.4.2) Insert the threaded bush (39) of screw (11) into its seat (A) in the mobile arm (17) (see

detail in Fig. 16); use the hand-wheel (12) to completely open the mobile arm.

7.4.3) Place the drill on the rail at the point to be drilled and clamp it by tightening the handwheel (12) fully down: the positioning template will automatically position the cutter or drill bit

in line with the designated axis; if precise positioning is necessary to the longitudinal rail axis, use the reference pin (01).

7.4.4) For rapid drill release, simply back-oﬀ the handwheel (12) by approximately two complete turns, and while supporting the drill by its grip (09), pull the handwheel towards you. The threaded bush (39) will disengage the seat (A) in the mobile arm (17) which will open automatically, freeing the drill. In this way, the operator can rapidly remove the machine from the track in case of danger or move on to drill another hole. Thus, the next track engagement operation will be considerably simpliﬁed: after positioning the drill at the point to be drilled, simply push the handwheel forwards so that the threaded bush engages the seat (A) of the mobile arm. Now, a few turns on the hand-wheel (12) will be suﬃcient to engage the drill correctly on the rail.

FIG. 16 – POSITIONING OF THE DRILL

8. FUEL PREPARATION

WARNING

- Petrol is extremely ﬂammable and explosive.  DO NOT SMOKE.

- Refuel in a well ventilated area away from ﬂame or sparks.

- Stop engine and allow it to cool before refueling.

When handling petrol:

- Risk of intoxication, avoid inhalation of petrol vapours.

- Risk of irritation, avoid prolonged and repeated contact with skin.

- Exhaust gas contains carbon monoxide, an odourless and deadly poison.

- Do not run engine in an enclosed area.

- To avoid a serious burn, do not touch a hot engine or exhaust.

- The engine becomes hot during operation.

- To avoid an electric shock, do not touch spark plug, plug cap or spark plug lead during engine running.

The rail drill features a two-stroke petrol engine run on a 2% (1:50) oil/petrol mixture; a calibrated measuring cylinder is supplied for this purpose.

Always use engine oil for two-stroke engines.

This engine is certiﬁed to operate on unleaded regular grade petrol only. A minimum of 89 octane on the antiknock index is recommended.

Warning: do not remove or alter in any way, the valve in the cap of the fuel tank.

9. STARTING THE ENGINE

Before starting the engine, make sure that:

- the spindle is completely retracted (see § 5).

- the accelerator control lever is completely closed (0).

9.1) Move engine "ON/OFF" switch to the “ON” position (Fig. a).

9.2) Repeatedly operate the fuel pump until fuel ﬂows through the

overﬂow pipe (Fig. b).

9.3) Make sure that the accelerator lever is in position "0". Only with a cool engine, set the ‘choke lever’ upwards, on the left side in starting position (Fig. c); when engine is warm or in case of high ambient temperature, set this lever downward in working position (Fig f).

9.4) Pull sharply on the starting rope and then release slowly; the engine before ignition, may require more than one operation (Fig. d).

Do not over-extend the starting rope and always release it slowly once the motor is running; a sudden release could damage the starting system.

If the engine does not start, do not repeatedly pull the starting rope with the ‘choke lever’ in start position. This could create a fuel excess in the cylinder and make ignition more diﬃcult. In this case, set the lever in working position and repeat the starting operation. Once started change the speed of the engine twice to allow the remaining air to leave the carburettor.

9.5) Just after starting, accelerate the engine gradually before starting any activity, then set the accelerator lever in "1" position (Fig. e) till the ‘choke lever’ automatically returns, then set it again in "0" position.

9.6) Allow the engine to warm up for approximately 2 minutes then set the accelerator lever in "1" position of maximum acceleration and start to drill.

9.7) To stop the engine move the “ON/OFF” switch to the “OFF” position.

9.8) Idling speed adjustment: if necessary, adjust the idling screw (Fig. f), so that the engine maintains a stable idling speed (2800 rpm).

9.9) Carburettor adjustment

The carburettor has been factory previously adjusted. The control system of the gas emissions applied to this motor consists of a carburettor and ignition system which guarantee the best results. The carburettor is so adjusted to provide the air/fuel mixture required to achieve low con-

: speed increases

: speed decreases

sumptions and low emissions of injurious gas.

The engine will perform at its optimum after a “running-in” period of approximately 200 drilling operations.

10. DRILLING

Before operating the drill, activate the coolant system (§ 4).

10.1) Drill ﬁtted with “short” type broach cutter (for drilling thicknesses up to 25 mm).

The drilling sequence may be started with the drill ﬁtted with the broach cutter (§ 6.1), position-

ing jig (§ 7.2), the drill being clamped to the rail (§ 7.3), as follows:

10.1.1) Connect the female quick-coupling of the SR5000 cooling system to the male attachment (35) on the drill.

10.1.2) Open the tap (02) ﬁtted on the tank tube.

10.1.3) Using the lever (36) bring the guide bit almost in contact with the rail (Fig. 17a);

keeping the release pawl (39) pressed, release the lever from its cup and return it to the initial position (Fig. 17b), which will enable the travel of the lever (36) to be used in the most advantageous way.

Fig. 17a Fig. 17b

FIG. 17 – DRILLING

Fig. 17c

10.1.4) Start the engine following instructions to § 9.

10.1.5) Proceed to drill by initially applying light pressure on the lever (36), increasing the pressure progressively, avoiding jolts, and ﬁnally relieving the pressure in the exit phase. When drilling close to raised letters on the rail the initial pressure must be extremely light until the lettering disappears, otherwise the cutter may be damaged.

10.1.6) The guide bit will enable the lubrocoolant to be discharged throughout the drilling

process.

10.1.7) When the drilling has been completed, fully retract the spindle, stop the engine by positioning the relevant switch to "OFF" position, and make sure that drilling swarf is

removed before recommencing drilling.

10.1.8) After drilling, it is advisable to remove all swarf from the tool and spindle area.

10.2) Drill ﬁtted with “long” type broach cutter (for drilling thicknesses of up to 50 mm).

Follow the sequence described in § 10.1, taking care to position the drill on the rail by keeping

the spindle fully withdrawn.

FIG. 18 – DRILLING

Approach

Start drilling

with discharge of lubrocoolant

Drilling

Finish drilling

with removal of swarf and switching oﬀ of lubrocoolant

FIG. 19 – COOLANT OPERATION WITH BROACH CUTTER

10.3) Drill ﬁtted with special spiral bit

Follow the sequence described in § 10.1, taking care to position the drill on the rail by keeping the spindle fully withdrawn. Bear in mind that the cooling circuit, instead of being automatically opened and closed by the guide bit, is kept open at all times by the DPE spacer ﬁtted on the spigot of the spiral bit; it must therefore be activated, by opening the tap (02), before starting to drill, then switched oﬀ after drilling by closing the tap.

FIG. 20a PE 70 - PE 165 spiral bits (drilling diameters from 7 to 16.5 mm)

use only for APE...,

not required for APED...

FIG. 20b PE 170 - PE 275 spiral bits (drilling diameters from 17 to 22 mm)

FIG. 20 – COOLANT OPERATION WITH SPIRAL BIT

11. SPA... POSITIONING PLATE

11.1) Instruction for drilling close to rail heads

FIG. 21

11.1.1) Fit the MPAF... positioning template corresponding to the rail to be drilled (see § 7.3).

11.1.2) Insert the SPA... positioning plate (03) relating to the rail to be drilled in the appropriate

housing (see Fig. 21).

11.1.3) Insert the locking pin (02) in one of the two holes of the connection plate.

11.1.4) With the spindle fully withdrawn position the drill close to the rail head without clamp-

ing it.

11.1.5) Slide the drill so that: – the curved end of the SPA... plate is ﬂush against the rail head.

– the MPAF... positioning template is ﬂush against the locking bolt (02).

11.1.6) Clamp the drill in this position by tightening the handwheel fully, and commence drilling

(see § 8.1).

11.1.7) To drill the second hole in the rail, repeat operations 11.1.5 - 6 with the locking pin (02) inserted in the second hole of the SPA... plate.

For clarity the drilling machine is not shown.

FIG. 22 – POSITIONING

11.2) Drilling in line with the rail heads (Ref. to Figs. 23-24)

11.2.1) Fit the MPAF... positioning template corresponding to the rail to be drilled (see § 7.3).

11.2.2) Fit the MRF clamp on the head of the rail, keeping it in contact with the rail head at a

point which deﬁnes the origin of the drilling centres, by locking it in position with the lever. The lever is provided with a return pushbutton for moving in any direction after locking. (See Fig. 23)

11.2.3) Insert the SPA... positioning plate so that the curved part is facing upwards.

11.2.4) Insert the locking pin (02) in one of the two holes of the connection plate.

11.2.5) With the spindle fully withdrawn, position the drill on the rail close to the MRF clamp,

without locking the spindle.

11.2.6) Slide the drill so that: – the curved end of the SPA... plate is ﬂush against the MRF clamp on theside iden-

tifying the origin of the distances. – the MPAF... positioning template is ﬂush against the locking bolt (02). (see Fig. 24).

11.2.7) Clamp the drill in this position by tightening the handwheel fully and commence drilling

(see § 10.1).

11.2.8) To drill the second hole in the rail, repeat operations 11.2.6 - 11.2.7 with the locking pin (02) inserted in the second hole of the SPA... plate.

FIG. 23 – ASSEMBLY OF THE MRF CLAMP

For clarity the drilling machine is not shown.

Origin of the distances

FIG. 24 – POSITIONING

Origin of the distances

12. STORING THE DRILL

When the work has been completed, store the drill by proceeding as follows:

12.1) Depressurise the tank of the SR5000 coolant unit (see § 4), close the tap (02) on the tube from the tank and disconnect the quick-coupling (03).

12.2) Carefully clean the drill, particularly in the spindle area, removing machining waste (swarf, etc.) and any deposits of lubricating coolant.

12.3) Fully withdraw the spindle.

12.4) Place the drill and the SR5000 cooling unit in a sealed place free from dust, moisture and

the risk of accidental impact.

For better protection Cembre recommends the use of the VAL P24 plastic carrying case or VAL P24-CS (variant with folding handle and wheels, see Fig. 25) designed for this purpose (see § 3.2). The DBG-F2 moving arm device allows the drill to be housed and locked in the case. Suitable housings are also provided in the plastic case for containing the most commonly used accessories.

ACCESSORIES

RAIL DRILL

ACCESSORIES

PLASTIC CASE

FIG. 25 VAL P24-CS PLASTIC CARRYING CASE

13. MAINTENANCE

Before you service or remove parts, stop the engine and allow it to cool.

Always remove the spark plug cap from spark plug when servicing the engine to prevent accidental starting.

After the ﬁrst 10 operating hours, proceed with oil sump change, as follows

(Ref. to Fig. 26a and 26b): – Remove the cap with the magnetic insert (24). – Remove the oil ﬁller cap (08). – Make sure that all the oil comes out by slightly tilting the drilling machine in order to make the operation easier. – Clean the cap (24) (see § 13.1.2). – Reassemble the cap. – Fill up the oil sump to the level indicator (see § 13.1.1) using the oil supplied with the drilling machine; it will be necessary to use about 100 ml. – Replace the oil ﬁller cap (08).

Ensure that disposal of used oil is in accordance with current legislation.

FIG. 26a

13.1) ORDINARY MAINTENANCE OF THE MACHINE

Every 20 hours of operation

13.1.1) Topping up oil (Ref. to Fig. 26a and 26b)

With the drill switched oﬀ and placed on a ﬂat surface, check the oil level in the crankcase by looking through the transparent inspection cover (16). The level must be approximately half way up the cover; if the level is low, top up the oil by unscrewing the cap (08) at the top of the crankcase and adding the quantity of oil required.

Only use the oil grade recommended in § 1. Never use regenerated or used oil. The oil must be clean.

FIG. 26b

13.1.2) Removal of metal residues from the crankcase

When the drill is positioned as shown in Fig. 26c unscrew the cap with magnetic insert (24) on which any metal residues present in the oil will have collected. Carefully clean the magnetic insert with a clean rag and screw it back in to the appropriate housing.

FIG. 26c – REMOVAL OF METALLIC WASTE

Every 50 hours of operation

13.1.3) Checking of screws

– Check and re-tighten all screws where necessary.

13.1.4) Lubrication (Ref. to Figs. 31 and 32) – Lubricate the spindle support housing by means of the appropriate lubricator (21), the screw (07) of the DBG-F2 clamping device.

13.1.5) Coolant ﬁlter cleaning (Ref. to Fig. 26d) The coolant circuit of the drilling machine is provided with anti-impurity ﬁlter; should an evident decrease of the ﬂow of the lubrocoolant occur, it could be necessary to clean the ﬁlter in the following way: – Using a 14 mm key, unscrew the coupling (02). – Extract the ﬁlter and clean it carefully. – Reassemble the ﬁlter into the coupling (02) as shown in the Fig. 26d and fully tighten the coupling.

anti-impurity ﬁlter

FIG. 26d – COOLANT FILTER CLEANING

13.2) ROUTINE ENGINE MAINTENANCE

13.2.1) Fuel tank cap

A breather passage is incorporated in the tank cap.

Tank cap

Tappo

If this passage is clogged, the fuel will not ﬂow into the carburetor, causing problems with starting or running the engine. At the same time, make sure that the base

Breather

of the breather assembly is ﬁtted ﬁrmly into the groove inside the tank cap, as shown.

Breather

Sfiato

passage

Breather

Membrana

Gancio

assembly

Fuel tank

Serbatoio

Every 20 hours of operating

13.2.2) Fuel ﬁlter cleaning (Ref. to Fig. 27)

– Pick the grommet out of the fuel tank and remove the fuel ﬁlter assembly from the fuel tank together with the grommet and the fuel tube to keep dust, entering from the fuel ﬁlter. – Clean the fuel ﬁlter assembly in a bath of high ﬂash-point solvent. – Dry the fuel ﬁlter assembly before reassemble.

Improper use of solvents can result in ﬁre or explosion.

Tube

Fuel tank

Transparent

overﬂow tube

Grommet

Filter

FIG. 27 – FUEL FILTER CLEANING

13.2.3) Air ﬁlter cleaning (Ref. to Fig. 28) – Manually remove the holding screws of the air cleaner cup. – Remove the ﬁlter element. – Wash the ﬁlter element in detergent and water and dry it thoroughly. – Reassemble all parts.

Operating in dusty condition may require more frequent maintenance than above. Do not operate the engine with air ﬁlter removed.

FIG. 28 – AIR FILTER CLEANING

Every 50 hours of operating

13.2.4) Spark plug cleaning (Ref. to Fig. 29)

– Disconnect the spark plug lead and with a spark plug key remove the spark plug. – Clean the electrode, taking care not to damage the insulation. – Check and adjust if necessary the electrode gap (0.6 mm - 0.7 mm). – Install and tighten the spark plug to 14 Nm, then connect the spark plug lead. – In case of plug replacement, use type NGK BPMR7A or equivalent:

BOSCH WSR5F / DENSO W22MPR-U / CHAMPION RCJ6Y.

FIG. 29 – SPARK PLUG CLEANING

Spark arrester

13.2.5) Spark arrester cleaning (Ref. to Fig. 30)

– Remove the spark arrester from the exhaust opening. – Clean deposits from the spark arrester screen by brushing it. – Relocate the spark arrester.

FIG. 30 – SPARK ARRESTER CLEANING

13.2.6) Checking of screws

– Check and re-tighten all screws where necessary.

13.3) SPECIAL MAINTENANCE OF THE DRILL

The special maintenance operations require the intervention of qualiﬁed personnel only, please contact Cembre (See § 15).

13.4 STORING THE DRILL FOR LONG PERIODS

– Completely empty the fuel tank. – Start the engine and let it run until it stops, so that all fuel is exhausted from the machine. – Remove the spark plug. – Pour 3-5 cm – Repeatedly pull gently on the starting rope so that the dispersion of the oil in the cylinder is achieved reinstall the spark plug. – With a clean cloth wetted with engine oil, than clean all metal parts of the machine. – Store the drilling machine in its appropriate case or in a dry environment, protecting it against accidental damage and dust.

of oil into the cylinder.

14. WARNINGS

14.1) Regularly check for correct tightening (torque) of the ﬁxing screws of the drill cutters and

the positioning templates.

14.2) Avoid pressure jolts on the advance lever during drilling.

14.3) Always make sure that drilling swarf is properly removed before starting to drill a new

hole.

14.4) Incomplete clamping of the drill on the rail to be drilled may lead to the breakage or ac celerated wear of cutters and damage to the spindle shaft bearings.

14.5) If it is necessary to operate the drill without the cutter inserted, remove the locking grub screws from the spindle shaft.

14.6) Avoid leaving the SR5000 tank under pressure and exposed to sunlight for long periods of time.

14.7) Should the DBG-F2 clamping device be removed make sure, by reassembling it, the two blocking screws are ﬁrmly fastened.

The guarantee is void if parts used are not

When ordering spare parts always give the following information:

- spare part code

- spare part description

- drilling machine model

- drilling machine serial number

FIG. 31 – DRILL ASSEMBLY

Cembre

original spares.

6001209 6900060 6001731 6001198 2870261 6001146 6340160 6001397 6001195 6003754 6003755 6003613

Code N°

Magnetic cap

Screw M 4x8

Guard

Lubricator

Front plate

Drilling spindle

M8x10 grub screw

Complete air valve

Level gauge

Reservoir+valve cap

Starting handgrip

Engine

Item

6003753

6003752

6380330

6003612

6003034

6001166

6490050

6001941

6360480

6001176

6001428

6001950

QtyDescription

Air cleaner element

Spark plug

Handle

Complete handgrip

Cap

Accelerator lever

Carriage handle

Complete spindle lever

O-ring

Lever release pawl

Complete cooling connection

Body

Item

DescriptionCode N°

1 1 1 1 1 1 1 1 1 1 1 1

Qty

11112222242411111111111221211111111

14 15

Spacer

Blocking screw

Complete bush

Spring support spacer

Spring

M 5 self-locking nut

ø 8x50 cilindrical pin

M5 ball dowell

M 6x18 screw

M 8x25 screw

ø 8 elastic washer

ø 4x10 cylindrical pin

ø1,8x35 split pin

TDB 1 termination

ø1,8x35 split pin

TDB 6 terminatin

Split pin

TDB 3 termination

ø10 circlip

Left support shoulder

Right support shoulder

Blocking side plate

M 8x10 grub screw

Handgrip

Hand-wheel

Blocking screw

Spacer

Bush

Cup spring

ø 2,5x16 split pin

Blocking support

373635343332312928

6001155

6002871

6001762

6001768

6001769

6180201

6001776

6760378

6340612

6900348

6650144

6900314

04 0302

6760222

6140082

6001138

6140082

6001775

6140080

6001137

6040421

6001156

6001907

6001906

6001757

6001772

6340160

6380310

6001150

6001151

6001659

6001152

6520422

6140085

6001145

Qty

Reference pin

6001281

Code N° Item Description

FIG. 32 – DBG-F2 RAIL WEB CLAMPING DEVICE

APPENDIX “A”

Factors which inﬂuence the number of holes that can be made according to the cutter used: – Hardness of the material to be drilled. – Thickness to be drilled. – Stability of the drill clamping and correct assembly of the drill cutters. – Suitable lubrocooling (lubrication/cooling) to keep the temperature of the cutter low so as

not to compromise the eﬃciency of the cutting edges, whilst at the same time facilitating the removal of swarf. – Contact time of the cutting edges of the cutter with the material to be drilled; bear in mind that the faster the hole is made the greater the eﬃciency.

– Observance of these basic rules:

1) Commence drilling by exerting light pressure on the advance lever, progressively increas ing and then relaxing it when the cutter is in the exit phase.

2) Avoid pressure surges and advance according to the diameter of the drilling diameter, to avoid scratching the material or damaging the cutting edges of the cutter.

3) Remember that a cutter with eﬃcient cutting edges requires a lower pressure than one with which a certain number of holes have already been made.

4) When holes are made close to raised lettering on the rails, commence drilling with very light pressure until the lettering disappears, to avoid possible breakage of the cutter.

5) Bear in mind that when operating on very hard rails, as in the case of quality 1100 steel, it is advisable to increase the lubrocoolant ﬂow rate.

15.

RETURN TO Cembre FOR OVERHAUL

In the case of a breakdown contact our Area Agent who will advise you on the problem and give you the necessary instructions on how to dispatch the tool to our nearest service Centre; if possible, attach a copy of the Test Certiﬁcate supplied by Cembre together with the tool or ﬁll in and attach the form available in the “ASSISTANCE” section of the Cembre website.

Cembre Ltd.

Dunton Park Kingsbury Road, Curdworth - Sutton Coldeld West Midlands B76 9EB (Great Britain) Tel.: 01675 470440 - Fax: 01675 470220 E-mail: sales@cembre.co.uk www.cembre.co.uk

Cembre S.p.A.

Via Serenissima, 9 25135 Brescia (Italia) Telefono: 030 36921 Telefax: 030 3365766 E-mail: sales@cembre.com www.cembre.it

Cembre S.a.r.l.

22 Avenue Ferdinand de Lesseps 91420 Morangis(France) Tél.: 01 60 49 11 90 - Fax: 01 60 49 29 10 CS 92014 – 91423 Morangis Cédex E-mail: info@cembre.fr www.cembre.fr

Cembre España S.L.

Calle Verano, 6 y 8 - P.I. Las Monjas 28850 Torrejón de Ardoz - Madrid (España) Teléfono: 91 4852580 Telefax: 91 4852581 E-mail: comercial@cembre.es www.cembre.es

Cembre GmbH

Heidemannstraße 166 80939 München (Deutschland) Telefon: 089 3580676 Telefax: 089 35806777 E-mail: sales@cembre.de www.cembre.de

Cembre Inc.

Raritan Center Business Park 181 Fieldcrest Avenue Edison, New Jersey 08837 (USA) Tel.: 732 225-7415 - Fax: 732 225-7414 E-mail: Sales.US@cembreinc.com www.cembreinc.com

www.cembre.com

This manual is the property of Cembre.

Any reproduction (in full or in part) is forbidden without the prior written permission of Cembre.

Cembre reserve the right to modify the speciﬁcations in this manual without prior notice.

cod. 6261139

Cembre LD-1P-ECO Operation And Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual