15 M 073 E
ENGLISH
Cerfied Quality
Management System
Cerfied Environmental
Management System
RAIL DRILL TYPE
LD-2E
Cerfied Occupaonal
Health & Safety
Management System
LD-2E-110
LD-4EF
OPERATION AND MAINTENANCE
MANUAL
1
DESCRIPTION OF THE DRILLS:
LD-2EN
LD-2EN-110
LD-4EN
basic drills
LD-2E
LD-2E-110
LD-4EF
basic drills complete
with DBG-F2 railweb
clamping device
2
ATTENTION
–
Before using the rail drilling, carefully read the instructions contained in this manual.
SAVE THESE INSTRUCTIONS: this manual contains important safety and operating
instructions for the drilling machine.
–
The degree of protection of the drilling machine against moisture is classified
“ordinary" (EN 50144-1 Standard).
Do not expose the rail drilling to rain and moisture; possible infiltrations of water
inside the electric motor determines the risk of electric shocks.
Mobile electric devices used outdoor must be connected to the supply by inter posing a safety interrupter for breakdown current.
–
DISCONNECT always the power supply when servicing the drill:
before removing the broach cutters, spiral bits, positioning templates etc.
–
During drilling keep your hands outside the danger area.
–
Always wear protective glasses and working gloves.
–
Avoid wearing clothes which may present a risk to personal safety.
Following information applies
in member states of the
European Union:
USER INFORMATION
the reduction of hazardous substances in electrical and electronic equipment, including the
disposal of waste”.
The ‘Not in the bin’ symbol above when shown on equipment or packaging means that the
equipment must, at the end of its life, be disposed of separately from other waste.
The separate waste collection of such equipment is organised and managed by the manufacturer. Users wishing to dispose of such equipment must contact the manufacturer and follow the
prescribed guidelines for its separate collection.
Appropriate waste separation, collection, environmentally compatible treatment and disposal
is intended to reduce harmful environmental effects and promote the reuse and recycling of
materials contained in the equipment.
Unlawful disposal of such equipment will be subject to the application of administrative sanctions provided by current legislation.
3
in accordance with “Directives 2002/95/EC and 2002/96/EC rgarding
1. GENERAL CHARACTERISTICS
Drilling capacity (*):
Speed without load:
Electric motor:
Supply:
Power rating:
Automatic switch:
Weight:
Weight with "DBG-F2":
Recommended
gear sump oil:
LD-2E
Ø 7 ÷ 33 mm
310 rpm
LD-2E-110
Ø 7 ÷ 33 mm
310 rpm
LD-4EF
Ø 7 ÷ 40 mm
250 - 280 rpm (**)
Single phase, double insulation
220 / 230 V - 50 Hz
110 / 120 V AC-DC
220 / 230 V -50 Hz
1800 W
protection against overheating caused by a current overload
and against unintentional start up following a drop in voltage, by
means of an automatic switch equipped with thermal cut-out
and underpower relay.
14 kg
17 kg
MOBIL DTE OIL LIGHT or ESSO TERESSO 32
or equivalent
Air Noise:
(Directive 2006/42/EC
annexe 1, point 1.7.4.2
letter "u")
see
"APPENDIX B"
page 28
"APPENDIX C"
page 29
Vibrations:
(Directive 2006/42/EC
annexe 1, point 2.2.1.1)
(*) with broach cutters on thicknesses up to 50 mm
with special spiral bits on thicknesses up to 45 mm
(**) Two speeds: 280 rpm with broach cutters and spiral bits diameter smaller than 28 mm;
250 rpm with broach cutters diameter between 28 to 40 mm inclusive.
see
4
2. ACCESSORIES SUPPLIED WITH THE DRILL
2.1) Guide bits for controlling the coolant 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 coolant system, for special
spiral bits, diam. 7 ÷ 27,5 mm.
2.3) Adaptor, type ARE, for external coolant connection, to be used
with the SR5000 coolant unit.
2.4) Grub screw, M8x10
– 4 pcs for clamping cutters or bits on spindle shaft.
2.5) Socket head cap screws, M6x16
– 4 pcs for securing drilling jigs to front plate.
2.6) Socket head cap screws, M6x25
– 4 pcs for securing special drilling jigs to 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 brush.
2.8) 140 ml oil bottle for gear sump.
Parts 2.1 to 2.8 are included in "ACCESSORIES KIT",
Code No 6001357.
2.9) Type SR5000 coolant unit.
5
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-2E, LD-2E-110 and LD-4EF.
3.1.1) DBG-LF2 device with moving arm
complete with TDB 7 end piece for clamping the drill to girder rails and for additional
special applications.
3.1.2) DBSN device for clamping the drill
to flange rails, for use in conjunction with
the MPAF templates. Using this device the
rail drill can remain clamped in the drilling
TDB 7
position even when trains pass over it.
TDB 1
TDB 6
TDB 3
3.2) “VAL LD” metal case for storing the drill complete with the DBG-F2 device, DBSN device
and VAL MPA tool case.
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, DBSN device
and VAL MPA tool case.
VAL P24-CS VAL LD-L
6
3.4) Templates for positioning the drill on 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 UIC 54 rail
– MPAF UIC60 on DRILLING AXIS of UIC 60 rail
• Note: Contact Cembre for selection of specific application
accessories.
3.5) MPAU universal positioning template suitable both for repairing existing holes on various fittings, and for drilling disused rails.
3.6) SPA positioning plates for drilling rail heads
with a centre-to-centre distance established
in the Railway boards standards, without the
need for marking out; for use in conjunction
with MPAF... positioning templates.
3.7) MRF clamp to be applied as a reference to the
head of rails for use, in conjunction with SPA...
positioning plates, for in-line drilling of rail heads,
with established centre-to-centre distance.
3.8) VAL MPA tool case suitable for storing
the accessories indicated in 3.5 - 3.8, and the
drilling tools.
7
3.9) Broach cutters
BROACH CUTTERS FOR RAILS IN STEEL QUALITY 700-900-1100 (UIC 860.0)
Ø
mm
13
13,5
14
16
17
17,5
18
19
20
21
22
23
24
25
26
27
27,5
28
29
30
31
32
33
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 cutters resharpening must be carried out in compliance with appropriate modes of operation which
allow the best result.
8
3.10) Spiral bits
APED...
FIG. 1
h
ø
APE...
L max
L max
FIG. 2
SPECIAL SPIRAL BITS FOR RAILS IN STEEL QUALITY 700 - 900 - 1100 (UIC 860.0)
Spiral Bit
Ø
7
8
9
type
(*)
PE 70
PE 71
PE 80
PE 85
PE 90
PE 95
PE 100
PE 110
PE 120
PE 130AR
PE 135AR
mm
Figure
7,1
8,5
1
9,5
10
11
12
13
13,5
– The 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.
The drilling tools indicated in the tables guarantee optimum results. For tools of other types, check the di-
mensional compatibility (particularly the size of the attachment and the length).
L
max
mm
76
72
76
h
mm
1,4
1,6
APED 135/165
Adaptor
type
APED 701,2
APED 80
APE 90
APE 95
APE 100
APE 110
APE 120
APED 130
Figure
1
2
Ø
mm
14
16
17
17,5
18
19
21
22
24
27,5
Spiral Bit
type
(*)
PE 140
PE 160
PE 170AR
PE 175
PE 180
PE 190AR
PE 210AR
PE 220
PE 240AR
PE 275AR
ø
L
h
max
mm
mm
1,6
76
88
85
88
ONLY FOR LD-4EF
Adaptor
type
APED 135/165
: special high quality spiral bit.
(*) PE... AR
3.11) LR2 BIODEGRADABLE LUBROCOOLANT
3 litre container to be used in a 5-10 % solution, for optimum operation of both broach cutters
and spiral bits.
3.12 LR3 ANTIFREEZE CONCENTRATE
3 litre added to the lubrocoolant mixture in the right concentration will
maintain the lubrocoolant mixture fluid in negative temperature conditions.
9
3l
4. COOLANT UNIT TYPE SR5000 (Ref. to Fig. 3)
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
01
02
01 – Tank complete with hose
and max. pressure valve
02 – Tap
03 – Quick-coupling
17 – Vent valve
35 – Attachment valve
FIG. 3 – COOLANT UNIT
03
35
17
10
The drill is equipped with a coolant 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:
– Using a 17 mm hexagonal spanner unscrew the vent valve from its seat.
– Using the 4 mm allen key provided with the drill, remove the appropriate coolant 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 coolant 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 advancing lever (36) to advance
and retract the drilling spindle.
– Gently shake the machine to expel all fluid.
03
36
FIG. 4
35
4.1) ARE adaptor
For use with type SR5000 coolant unit. The ARE adaptor is inserted in the quick-coupling of the
tank tube (Ref. to Fig. 5), it 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 adaptor 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.
FIG. 5 – ARE ADAPTOR
11
ARE adaptor
5. SPINDLE ADVANCE LEVER (Ref. to Fig. 6)
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. 6).
FIG. 6
6b - With the release pawl (39) pressed, the lever is
released from its hub and can repeat the pre vious 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
produces a corresponding advance of the
spindle.
6c - With the hub released, moving the lever
towards the operator produces a corre sponding advance of this spindle.
FIG. 7
SELF-LOCKING NUT
12
6. PREPARING THE RAIL DRILL
DISCONNECT always the power supply 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 male hexagon key in the
appropriate intermediate gear housing (33) in the crankcase of the drill corresponding
to the feed handle (71) (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.
6.1.4) Clamp the cutter by fully tightening the grub screws by means of the 4 mm male hexagon
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
18
Guide bit PP..
07
FIG. 8 – ASSEMBLING BROACH CUTTERS
Guide bit PPL..
Long type broach cutter
Maximum drilling thickness: 50 mm
6.2) Assembling 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 in the crankcase of the drill corresponding to the
feed handle (see Fig. 11).
13
6.2.2) Insert into the spindle shaft, the DPE spacer required to activate the coolant system.
If it is necessary to use an APE... adaptor the bit must first be fitted in the corresponding
APE adaptor and locked with the appropriate grub screw, then the DPE spacer inserted.
Note: Adaptors type APED… (e.g. APED 135/165) 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 againt the inner
seat of the spindle: this will enable the DPE spacer to open the coolant circuit (see Fig. 10).
6.2.4) Clamp the bit by fully tightening the two grub screws (18) using the 4 mm male hexagon key.
APE ...
18
DPE
*
Bits PE ... (e.g. PE70)
07
Bits PE ... (e.g. PE 220)
DPE
* use only for APE, not required for APED
FIG. 9 – ASSEMBLING SPIRAL BITS
FIG. 11 – MANUAL SPINDLE
ROTATION
FIG. 10 – ASSEMBLING THE
BIT-SPACER UNIT
71
33
14
7. RAIL DRILL TYPE LD-2E ; LD-2E-110 ; LD-4EF
Code n. LD-2E ; LD-2E-110 ; LD-4EF each cover a basic drill (see page 1) complete with the
moving arm device DBG-F2 for clamping to the rail web and the track fittings (Ref. to Fig. 12).
The DBG-F2 clamping device consists of:
– Clamping unit
– Type TDB 1 end piece
– Type TDB 3 end piece
– Type TDB 6 standard end piece
– Socket head cap screws M 8x25 (2 pcs)
– Spring washers (4 pcs)
– Reference pin
and spring washers
FIG. 12 – DRILL WITH DBG-F2 DEVICE
15
M 8x25 screws
reference
pin
TDB 6
TDB 3
TDB 1
7.1) Assembling end pieces
TDB 1, TDB 6 and TDB 3 end pieces 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 TDB 3 end piece ensure that the positioning pawl is pointing down ward in relation to the bolt.
• When disassembling the TDB 6 end piece ensure that, after removing the pivot, the com plete assembly is slid away downwards without acting on the holding plate.
• Over-advancing the spindle after drilling must be avoided when using the TDB 1 and TDB3
end pieces.
holding
plate
TDB 1 end piece for switch blades
and composite frogs
TDB 3 end piece
for enlarging existing holes
on rails inherent in the application
of electrical connections and for
additional special applications.
FIG.13 – ASSEMBLY END PIECES
TDB 6 end piece for rails and stock rails
Seats to be used for
special applications.
positioning pawl
pointing downwards
16
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 (30) also supplied.
The assembly is illustrated in Fig. 14.
DBG-F2 Clamp
FIG. 14 – ASSEMBLY OF THE
30
TYPE “DBG-F2” CLAMP
Drilling machine
front plate
7.3) Assembly positioning templates (Ref. to Fig. 15)
NOTE: Only Cembre positioning templates and jigs are to be used with the rail drill.
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
MPAU
screws M6x16
FIG. 15 – ASSEMBLY OF TEMPLATES
17
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. 17); use the hand-wheel (12) to completely open the mobile arm.
7.4.3) Place the drill on the track at the point to be drilled and clamp it by tightening the handwheel fully down (12): 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 track axis,
use the reference pin (01).
7.4.4) For rapid drill release, simply back-off the hand-wheel (12) by approximately two complete turns, and while supporting the drill by its grip (09), pull the hand-wheel 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 hand-wheel forwards so that
the threaded bush engages the seat (A) of the mobile arm. Now, a few turns on the hand-wheel
will be sufficient to engage the drill correctly on the track.
36
09
12
0701
FIG. 16 – POSITIONING THE DRILL
(eg on UIC60 rail with MPAF UIC60 template)
17
39
39
11
11
18
17
17
A
17
<>
8. DRILLING (Ref. to Figs. 17-18)
N.B.: make sure the mains voltage corresponds to that on the drill rating plate.
N.B.: switch on the cooling system before starting the drill (§ 4).
8.1)
Drill fitted with “short” type broach cutter (for drilling thicknesses of up to 25 mm).
The drilling sequence may be started with the drill fitted with the broach cutter (§ 6.1), clamping
end piece (§ 7.1), positioning template (§ 7.3), the drill being clamped to the rail (§ 7.4), as follows:
8.1.1) Connect the female quick-coupling of the SR5000 coolant unit to the male coupling (12)
on the drill.
8.1.2) Open the tap (02) fitted onn the coolant unit hose.
8.1.3) 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. 17c
36
39
8.1.4) Connect the electric plug and press the automatic switch (position "I") (Fig. 17d)
CAUTION: the automatic switch is equipped with
protection against motor overheating and with an underpower relay; should the motor overheat or there is a fall
in voltage below the relay cut-out setting, the switch will
move into the "0" position. At this stage, if the conditions
are correct, the switch will have to be re-set manually.
FIG. 17d
19
AUTOMATIC SWITCH
8.1.5) ONLY FOR LD-4EF DRILL
Set the motor speed, by means of the selector
switch under the automatic switch (see Fig.
17e), in correlation to the diameter of the hole
to be. We suggest to use the standard speed
(280 rpm) for holes smaller than ø 28 mm and
the lower speed (250 rpm) for holes between
dia 28 and 40 mm inclusive.
ONLY FOR LD-4EF DRILL:
switch for changing of the spindle speed
FIG. 17e
SPEED CHANGE SWITCH
8.1.6) 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 markings on the rail the initial pressure must be
extremely light until the markings disappear, otherwise the cutter may be damaged.
8.1.7) The guide bit will enable the lubrocoolant to be discharged throughout the drilling
process.
8.1.8) When drilling has been completed, fully retract the spindle, stop the motor by pressing
the automatic switch (position " 0 "), and make sure that drilling swarf is removed before
recommencing drilling.
8.1.9) After drilling it is advisable to remove all swarf from the tool and spindle area.
8.2) Drill fitted with “long” type broach cutter (for drilling thicknesses
of up to 50 mm).
Follow the sequence described in § 8.1, taking care to position
the drill on the rail by keeping the spindle fully withdrawn.
02
35
FIG. 18 – DRILLING
36
39
20
Approach
Start drilling
with discharge of
lubrocoolant
Drilling
Finish drilling
with removal of swarf and
switching off of
lubrocoolant
The slug is ejected upon completion
of the drilling operation
FIG. 19 – COOLANT DRILLING WITH BROACH CUTTER
8.3) Drill fitted with special spiral bit
Follow the sequence described in § 8.1, taking care to position the drill on the rail by keeping the
spindle fully withdrawn. Bear in mind that the coolant 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 27.5 mm)
21
DPE spacer
*
APE adapter
Spiral bit
FIG. 20 – COOLANT DRILLING WITH SPIRAL BIT
9.1) Instruction for drilling close to rail heads
9. SPA... POSITIONING PLATE
02
03
FIG. 21
9.1.1) Fit the MPAF... positioning template corresponding to the rail to be drilled(see § 7.3).
9.1.2) Insert the SPA... positioning plate (03) relating to the rail to be drilled in the appropriate
housing (see Fig. 21).
9.1.3) Insert the locking pin (02) in one of the two holes in the positioning plate.
9.1.4) With the spindle fully withdrawn position the drill close to the rail head without clamping
it.
9.1.5) Slide the drill so that:
– the curved end of the SPA... positioning plate is flush against the rail head.
– the MPAF... positioning template is flush against the locking bolt (02).
9.1.6) Clamp the drill in this position by tightening the hand-wheel fully, and commence drilling
(see § 8.1).
9.1.7) To drill the second hole in the rail, repeat operations 9.1.5 - 6 with the locking pin (02)
inserted in the second hole of the SPA... positioning plate.
For clarity the drill is not shown
in the figures
FIG. 22 – POSITIONING
02
22
9.2) Drilling in line with rail heads (Ref. to Fig. 23)
9.2.1) Fit the MPAF... positioning template corresponding to the rail to be drilled (see § 7.3).
9.2.2) Fit the MRF clamp on the head of the rail, keeping it in contact with the rail head at the
reference point of the drilling centres. Lock it in position with the lever. The lever is pro vided with a return pushbutton for moving in any direction after locking (See Fig. 23).
9.2.3) Insert the SPA... positioning plate so that the curved part is facing upwards.
9.2.4) Insert the locking pin (02) in one of the two holes of the connection plate.
9.2.5) With the spindle fully withdrawn, position the drill close to the MRF clamp, without lock-
ing the spindle.
9.2.6) Slide the drill so that:
– the curved end of the SPA... plate is flush against the MRF clamp on the side identify-
ing the reference point of the distances.
– the MPAF... positioning template is flush against the locking bolt (02) (see Fig. 24).
9.2.7) Clamp the drill in this position by tightening the hand-wheel fully, and commence drilling
(see § 8.1).
9.2.8) To drill the second hole in the rail, repeat operations 9.2.6 - 7 with the locking pin (02)
inserted in the second hole of the SPA... plate.
FIG. 23 – ASSEMBLY OF MRF CLAMP
23
02
For clarity the drill is not shown in the
figures
Reference point of distances
02
FIG. 24 – POSITIONING
Reference point of distances
24
10. STORING THE DRILL
When work has been completed, store the drill by proceeding as follows:
10.1) Depressurise the tank of the SR5000 coolant unit (see § 4), close the tap (02) on the hose
and disconnect the quick-coupling (03).
10.2) Carefully clean the drill, particularly in the spindle area, removing machining waste (swarf,
etc.) and any deposits of lubrocoolant.
10.3) Fully withdraw the spindle.
10.4) Place the drill and the SR5000 coolant 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 LD metal case designed for
this purpose (see § 3.4), which enables the drill to be inserted thanks to the DBG-F2 clamping
device, and to be locked in the case. Suitable housings are also provided in this case for the DBSN
clamping device and the VAL MPA tool case.
DBSN
VAL MPA
RAIL DRILL
FIG. 25 - STORAGE CASE
25
VAL LD
11. MAINTENANCE
Before servicing or maintenance, stop the motor and disconnect the plug
from the electric source.
After first 10 operating hours, proceed with sump oil
change, as follows:
(Ref. to Fig. 26a and 26b)
– Remove the cap with the magnetic insert (21).
– Remove oil filler cap (07).
– Make sure that all the oil comes out by slightly tilting
the drill.
– Clean up the cap (21) (see § 11.1.2).
– Reassemble the cap (21).
– Fill the sump with oil to the level indicator (see § 11.1.1)
using the oil supplied with the drilling machine; it will
be necessary to use about 140 ml oil.
– Replace the filler cap (07).
07
Ensure that disposal of used oil is in
accordance with current legislation.
11.1) ORDINARY MAINTENANCE OF THE DRILL
Every 20 hours of operation
11.1.1) Topping up oil (Ref. to Figs. 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 appropriate transparent inspection cover (13). The
level must be approximately half way up the cover; if
the level is low top up the oil by unscrewing the cover
(07) 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
FIG. 26a
13
21
26
11.1.2) Removal of metallic residues from the crankcase
When the drill is positioned as shown in Figure unscrew
the appropriate cap, with magnetic insert (21) on which
any metallic residue will have collected.
Carefully clean the magnetic insert with a clean rag and
screw it back in the appropriate housing.
Every 50 hours of operation
11.1.3) Checking of screws
– Check and re-tighten all screws where necessary.
11.1.4) Lubrication
Lubricate the spindle support housing by means of the appropriate lubricator (35), the screw of
the clamping device with moving arm, DBG-F2 and DBG-LF2.
11.1.5) Coolant filter cleaning (Ref. to Fig. 27)
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. 27 and fully tighten the
coupling.
anti-impurity filter
21
02
FIG. 27 –
COOLANT FILTER CLEANING
11.2) ROUTINE MOTOR MAINTENANCE (Ref. to Fig. 28)
Every 50 hours of operation
11.2.1) Changing the brushes
After disconnecting the power plug check the degree of wear of the brushes; if necessary replace
them by proceeding as follows:
– Unscrew with a screwdriver the two screws located underneath the protective covers.
– Remove the two protective covers.
– Replace the brushes.
– Reassemble the two protective covers.
– Tighten the locking screws.
27
Brush
FIG. 28 – CHANGING THE BRUSHES
11.3) SPECIAL MAINTENANCE OF THE DRILL
The special maintenance operations require the intervention of qualified personnel only, Please
contact Cembre (See § 13).
APPENDIX “A”
Factors which influence the number of holes that can be made according to the tool used.
– Hardness of the material to be drilled.
– Thickness to be drilled.
– Stability of the drill clamp and correct assembly of the cutter/bit.
– Suitable lubrocooling (lubrication/cooling) to keep the temperature of the tool low so as
not to compromise the efficiency of the cutting edges, whilst at the same time facilitating the
removal of the swarf.
– Contact time of the cutting edges of the cutter/bit with the material to be drilled;
bear in mind that the faster the hole is made the greater the efficiency.
– Observance:
1) Commence drilling by exerting light pressure on the advancing lever, progressively
increasing and then relaxing it when the tool is in the exit phase.
2) Avoid pressure jolts and only advance according to the drilling diameter to avoid scratching
the material or damaging the cutting edges of the cutter/bit.
3) Remember that a tool with efficient cutting edges requires a pressure lower than that ap plied to 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 tool.
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.
28
APPENDIX “B” FOR LD2E AND LD2E110 DRILLS
Air noise (Directive 2006/42/EC, Annexe 1, point 1.7.4.2, letter u)
– The continuous equivalent weighted level (A)
of noise pressure at the working place L
is equal to ............................................................. 85,8 dB (A)
pA
– The maximum value of instantaneous weighted noise
pressure C at the working place L
– The level of noise force produced by the machine L
is lower than ................................................................. 130 dB (C)
pCPeak
WA
is equal to ................................................................................................................................................. 96,6 dB (A)
Protection of operators against risksof exposure to noise during work.
Cembre drills type LD-2E and LD-2E-110 are designed and constructed according to EEC
directives 80/1107 and 86/188 relating to the protection of operators against risks arising from
exposure to chemical, physical and biological agents during work, and with particular regard to
the risk of exposure to noise.
This has enabled a range of drills to be manufactured for drilling rails and track equipment, at
reduced noise levels.
The degree of exposure of an operator to noise produced from this equipment depends on the
duration of the loading times and the intervals between exposures, and finally on the number
of holes made within the space of one working day.
For example, an operator using the drill correctly for making holes 19 mm in diam., with a type
RCV 190 broach cutter on rails classified as UIC 60, quality 900, producing up to 400 holes/day,
the daily personal exposure to noise, due solely to the use of the drill, is less than 80 dB (A); under
similar conditions producing 700 holes/day, the daily exposure to noise would be 82.1 dB(A).
Since noise levels vary according to the many different operating conditions, Cembre engineers
are available to give further details on the correct use of the drills.
Risks due to vibration
(Directive 2006/42/EC, Annexe 1, point 2.2.1.1)
The weighted root mean square acceleration value to which the arms of an operator are subjected
when using the drill machine does not exceed 2,5 m/s
29
2.
APPENDIX “C” FOR LD4EF DRILL
Air noise (Directive 2006/42/EC, Annexe 1, point 1.7.4.2, letter u)
– The continuous equivalent weighted level (A)
of noise pressure at the working place L
– The maximum value of instantaneous weighted noise
pressure C at the working place L
pCPeak
– The level of noise force produced by the machine L
is equal to ........................................................................................................................................... 93,4 dB (A)
Protection of operators against risks of exposure to noise during work.
Cembre drill type LD-4EF, is designed and constructed according to EEC directives
80/1107 and 86/188 relating to the protection of operators against risks arising from exposure
to chemical, physical and biological agents during work, and with particular regard to the risk
of exposure to noise.
This has enabled a range of drills to be manufactured for drilling rails and track equipment, at
reduced noise level.
The degree of exposure of an operators to noise produced from this equipment depends on the
duration of the loading times and the intervals between exposures, and finally on the number
of holes made within the space of one working day.
For example, an operator using the drill correctly for making holes 36 mm in diam., with a type
RCV 360 broach cutter on rails classified as UIC 60, quality 900, producing up to 150 holes/day,
the daily personal exposure to noise, due solely to the use of the drill, is less than 80 dB (A); under
similar conditions producing 300 holes/day, the daily exposure to noise would be 82.2 dB(A).
Since noise levels vary according to the many different operating conditions, Cembre engineers
are available to give further details on the correct use of the drills.
is equal to ....................................................... 84,7 dB (A)
pA
is lower than ............................................................130 dB (C)
WA
Risks due to vibration
(Directive 2006/42/EC, Annexe 1, point 2.2.1.1)
The weighted root mean square acceleration value to which the arms of an operator are subjected
when using the drill machine does not exceed 2,5 m/s
2.
30
12. WARNINGS
12.1) Always disconnect the electrical supply when working on the drill to replace cutters, bits,
positioning templates and/or end pieces for maintenance.
12.2) Regularly check for correct tightening (torque) of the fixing screws of the cutters/bits and
positioning templates.
12.3) Avoid pressure jolts on the advancing lever during drilling.
12.4) Always make sure that drilling swarf is properly removed before starting to drill a new
hole.
12.5) Incomplete clamping of the drill on the rail to be drilled may lead to the breakage or ac celerated wear of the cutter/bit and damage to the spindle shaft bearings.
12.6) If it is necessary to operate the drill without the cutter inserted, remove the locking grub
screws from the spindle shaft.
12.7) Avoid leaving the SR5000 coolant tank under pressure or exposed to sunlight for long
periods of time.
12.8) Should the DBG-F2 clamping device be removed when using the drilling machine in an
upright position, make sure that by reassembling it, the two locking screws are firmily
fastened.
13. RETURN TO
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 drill to our nearest service Centre;
if possible, attach a copy of the Test Certificate supplied by
or, if no other references are available, indicate the approximate purchase date and the drill
serial number.
31
Cembre
FOR OVERHAUL
Cembre
together with the drill
08
12
14
15
16
17
18
19
11
09
10
20
13
21
22
07
06
05
04
03
02
01
Guarantee conditions cease upon usage of non original spare parts.
When ordering spare parts always give the following information:
- spare part code
- spare part description
- drilling machine model
- drilling machine serial number
FIG. 29 – DRILL ASSEMBLY
32
12
14
15
16
17
18
19
11
09
10
20
13
21
22
09
10
11
12
13
14
15
16
17
18
19
20
21
22
33
6001209
6900060
6001731
6001198
6001397
6001144
6001146
6340160
6001195
-
22
Electric plug
21
Magnetic cap
20
Screw M 4x8
19
Guard
18
Lubricator
17
Complete air valve
16
Front plate
15
Drilling spindle
14
M 8x10 grub screw
13
Transparent inspection cover
12
Automatic switch
Item QtyDescriptionCode No
-
11
1
6001422
1
6380316
2
6380330
1
6001210
1
6001238
1
6001262
1
6360480
1
6001176
2
6001428
1
1
-
Electric motor
10
Brush
09
Handle
08
Handgrip
07
Cap
06
Carrying handle
05
Spindle advance lever
04
O-ring
03
Lever release pawl
02
Complete coolant connection
01
Body
Item QtyDescriptionCode No
1
2
1
1
1
1
1
1
1
1
1
11112222242411111111111221211111111
Qty
Spacer
Blocking screw
Complete bush
Spring support spacer
Spring
M 5 self-locking nut
Pin
ø 8x50 cilindrical pin
M5 ball dowell
373635343332312928
6001155
6002871
6001762
6001768
6001769
6180201
6001776
6760378
6340612
11
10
08
M 6x18 screw
M 8x25 screw
ø 8 elastic washer
27
26
25
6900348
6650144
6900314
36
34
ø 4x10 cylindrical pin
ø1,8x35 split pin
TDB 1 termination
ø1,8x35 split pin
TDB 6 terminatin
24
23
22
21
20
6760222
6140082
6001138
6140082
6001775
33
31
14 15
Split pin
TDB 3 termination
19
18
6140080
6001137
29
32
18
ø10 circlip
17
6040421
27
Pin
Left support shoulder
16
15
6001156
6001907
26
28
13
Right support shoulder
Blocking side plate
Pin
14
13
11
6001906
6001757
6001772
25
22
M 8x10 grub screw
10
6340160
19
Handgrip
09
6380310
Hand-wheel
Blocking screw
08
07
6001150
6001151
21
06
24
Spacer
6001659
Bush
Cup spring
05
04 0302
6001152
6520422
23
Blocking support
Reference pin
01
6001145
6001281
Description
Code N° Item
ø 2,5x16 split pin
6140085
09
35
07
06
05
04
02
03
01
17
34
16
20
37
FIG. 30 - “DBG-F2” RAIL WEB CLAMPING DEVICE
INDEX page
1. General characteristics ............................................................................................................................... 3
2. Accessories supplied with the drill ........................................................................................................4
3. Accessories to be ordered separately ...................................................................................................5
4. Type SR5000 coolant unit ..........................................................................................................................9
5. Spindle advance lever ............................................................................................................................. 11
6. Preparing the drill ..................................................................................................................................... 12
7. Rail drill type LD2E; LD2E110; LD4EF ....................................................................................... 14
8. Drilling ........................................................................................................................................................... 18
9. SPA... Positioning plate ............................................................................................................................ 21
10. Storing the drill .......................................................................................................................................... 24
11. Maintenance ............................................................................................................................................... 25
12. Warnings ...................................................................................................................................................... 30
13. Return to
Cembre
for overhaul ..................................................................................................... 30
Appendix “A” ......................................................................................................................................................... 27
Appendix “B” ......................................................................................................................................................... 28
Appendix “C” ........................................................................................................................................................ 29
35
Cembre Ltd.
Dunton Park
Kingsbury Road, Curdworth - Sutton Coldfield
West Midlands B76 9EB (UK)
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.com
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.U.
Calle Verano 6 y 8
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
any reproduction is forbidden without written permission.
Cembre:
reserves the right to make modifications and improvements to products without prior notice
This manual is the property of
Cembre
cod. 6261202
36
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