Cembre LD-2EY, LD-2ENY, LD-2EYGR Operation And Maintenance Manual

07 M 053 U

.

Cembre

.

Cembre

reserve the right to modify the specifi cations in this manual without prior notice.

Certified Quality

Management System

RAIL DRILL

LD-2EY

Certified Environmental

Management System

TYPE

Certified Occupational

Health & Safety

Management System

PATENTED

ENGLISH

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Telefax: 91 4852581
E-mail: [e-mail]
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Cembre Ltd.

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Tel.: [phone] - Fax: [phone]
E-mail: [e-mail]
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Phone: [phone]
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Telefon: [phone]
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Tel.: [phone] - Fax: [phone]
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This manual is the property of

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

Cembre

cod. 6261216

OPERA TION AND MAINTENANCE

MANUAL

Ref. LD-2ENY:

basic drill without clamping device

Ref. LD-2EY:

(LD-2ENY + DBG-Y)
basic drill complete
with railweb clamping
device type DBG-Y

Ref. LD-2EYGR:

(LD-2ENY + DBG-GR)
basic drill complete
with railweb clamping devi­ce type DBG-GR

INDEX

Rail drill type LD-2ENY ..............................................................................................2

1. General characteristics ..........................................................................................2

2. Accessories supplied with the rail drill ...................................................................3

3.

Optional accessories (to be ordered separately) ...................................................4

4. Type SR5000 coolant unit....................................................................................10

5. Spindle advancing lever.......................................................................................12

6. Preparing the rail drill ...........................................................................................13

7. Rail drill type LD-2EY ........................................................................................15

8. Drilling ..................................................................................................................19

9. Example of other rail drill applications .................................................................22

10. Special applications for

11. Storing the rail drill ...............................................................................................23

12. Warnings ..............................................................................................................24

13. Maintenance ........................................................................................................25

14. Return to

Appendix “A” ..............................................................................................................27

Appendix “B” ..............................................................................................................

Cembre

Cembre

for overhaul ..........................................................................29

rail drills ..........................................................22

page

28

134

NOTES

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 classifi ed “ordinary" (EN 50144-1 Standard).
Do not expose the rail drilling to rain and moisture; possible infi ltrations
of water inside the electric motor determines the risk of electric
shocks.
Mobile electric devices used outdoor must be connected to the supply
by interposing 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.

RAIL DRILL TYPE LD-2ENY

33

1. GENERAL CHARACTERISTICS

– Drilling capacity: ................................................................................∅ 9/32" to 1 1/2"

(with special twist drill bits: hole diameters of 9/32" to 1-1/8" on rails up to 3 1/2" thick)

(with broach cutters: hole diameters of 3/4" to 1-1/2" on rails up to 2 3/4" thick)

– Speed without load: ........................................................................................ 310 rpm

– Electric motor:

– single phase, double insulation
–

supply voltage:
– power rating:
– 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.

– Weight: .................................................................................................................31 lbs

– Weight:
– Recommended gear sump oil: MOBIL DTE OIL LIGHT

ESSO TERESSO 32
– For "Air noise" and "Risk due to vibration", see page 28.

2

........................................................................................120 V AC / DC

......................................................................................................1800 W

with “DBG-Y” clamping device

..............................................................38 lbs

or
or equivalent

2. ACCESSORIES SUPPLIED WITH THE RAIL DRILL

2.1) Pilot bits for controlling the cooling system:

for use with short broach cutters (7/8 " depth of cut)

– 1 pc PPC 2

for use with long broach cutters (2 " depth of cut)

– 1 pc PPL 2

2.2) Spacer, type DPE, for use with spiral bits and APE adaptor
for controlling the cooling system, do not required for APED adaptor.

09
10

11

2.3) Adapter, 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 shoes to the front plate.

2.6) Socket head cap screws, M6x25

– 4 pcs for securing special positioning shoes 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 brush (for removing the drilling swarf)

2.8) 4.7 fl oz (140 ml) oil tank for
the gear reduction.

2.9) Type SR5000 coolant unit.

(Accessories from pos. 2.1 to pos. 2.8 are included in the
“Kit of accessories for LD-2ENYY” having the code 6001909)

12

13

14
15
16
17
18

19

20

21

22

­6001209
6900060
6001731

6001198

6001397

6001144
6001146

6340160

6001195

6001818

Code No

Electric plug

22

Magnetic cap

21

Screw M 4x8

20

Guard

19

Lubricator

18

Complete air valve

17

Front plate

16

Drilling spindle

15

M 8x10 grub screw

14
13

Transparent inspection cover

12

Automatic switch

Item QtyDescription

1
1
2
1
1
1
1
1
2
1
1

6001368
6001422
6380316
6380330
6001210
6001238
6001262
6360480

6001176
6001428
6001997

Code No

Electric motor

11

Brush

10

Handle

09

Handgrip

08

Cap

07

Carrying handle

06

Spindle advance lever

05

O-ring

04

Lever release pawl

03

Complete coolant connection

02

Complete body

01

Item

1
2
1
1
1
1
1
1
1
1
1

QtyDescription

3

32

3. OPTIONAL ACCESSORIES (to be ordered separately)

3.1) "DBG-Y" device with moving arm for clamping

the rail drill to the rail web and track fi ttings, complete
with the TDB 6 termination.

08

07

06

05

04

03

02

01

* Always supplied with rail drill ref. LD-2EY

TDB 6

3.1.1) "DBG-LY" device specifi c for clamping the rail drill

to the girder rails (for example 128 GR or GGR 118). With
the specifi c shoes allows the positioning on both sides of
the rails, complete with theTDB 3 termination.

TDB 3

When ordering spare parts always give the following information:

- spare part code

- spare part description

- rail drill model

- rail drill serial number.

FIG. 28 – RAIL DRILL ASSEMBLY

31

3.1.2) "DBG-GR" device for clamping the rail drill in
correspondance of guard rail, complete with theTDB
1 termination.

Always supplied with rail drill ref. LD-2EYGR

4

3.2) "TST 50" two stage template

(to be used with specifi c DBG-AY clamp)
This device enables the drilling of 150 lb and alu­minium composite contact rails from one side.
Restart of work stroke: 1,97”
Typical application:
– Aluminium composite rail.
– 150 lbs contact rail.

1111122442111211121111111

Threaded bush

ø14 Circlip

ø10 Circlip

Spacer

Pin

ø 8 x 50 pin

M5 ball dowel

M 6 x 18 screw

Spring washer

M 8 x 25 screw

ø4 x 10 pin

ø1,8x35 Split pin

TDB 6 termination

Blocking side

Clamping support left shoulder

Clamping support right shoulder

M 8 x 10 grub screw

Clamping handle knob

Blocking lever

Compl. blocking screw

Thickness

Adjusting bush

Cup spring

ø2,5 x 16 Split pin

Clamping support

30292827262524232221201716131211100908070605040302

1

Drilling reference rod
01

3.3) "VAL LD" steel carrying case for
accommodating the complete drill with
the clamping device.
22 1/2" (L) x 13 1/2" (W) x 17 1/2" (H)

3.4) "VAL MPA" suitable for storage of rail shoes,
cutters and accessories

• 15 1/2” (L) x 13 3/4” (W) x 2 1/4” (H)

30

10

6001154

29

6001155

6700524

6040421

6001156

6760378

27

28

6340612

6900314

6650144

26

121113

6900348

6760222

6140082

25

24

14

6001775

6001751

6001756

22

23

15

6001754

6340160

6380310

21

16

6001150

6001658

20

17

6001152

6001659

19

18

6001145

6520422

6140085

6001281

Code N° Item Description Qty

3.5) "MPAU" UNIVERSAL RAIL SHOE for rail or for special
applications such as drilling #20 high speed switch points
(positioning not automatic).

3.5.1) "MPAU-10" UNIVERSAL SHORT RAIL SHOE for
rail or for special applications (positioning not automatic).

5

30

09

08

07

06

05

04

03

02

01

FIG. 27 – “DBG-Y” RAIL WEB CLAMPING DEVICE

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 T est Cerifi cate supplied by

Cembre

together with
the tool or, if no other references are available, indicate the approximate purchase date
and the tool serial number.

29

3.5.2) "MPAF..." SPECIFIC RAIL SHOES
Suitable for positioning the drill on running and guard
rails.

Enable the automatic position of the machine onthe drilling axis
(H) of each specifi c rail.

•

Note: Please contact

RAIL SHOES DRILLING ON RUNNING RAILS

TYPE OF

RAIL

40 LB ASCE 3 1/16"
60 LB ASCE 3 1/16"
80 LB ASCE 2 3/16”
85 LB ASCE 2 17/64”
85 LB PRR 2 1/16”
85 LB PS 2 15/64”
90 LB ARA-A 2 9/16”
90 LB ASCE 2 45/128”
100 LB ARA-A 2 3/4”
100 LB ARA-B 2 65/128”
100 LB ASCE 2 65/128”
100 LB DY 2 5/8”
100 LB NYNH&H 2 39/64”
100 LB RE 2 45/64”
100 LB RE-HF 2 45/64”
100 LB PRR 2 9/32”
100 LB PS 2 31/64”
105 LB DY/110 LB RE
112/115/119 LB RE 2 7/8”
122 CB 2 7/8”
127 LB DY 3 1/8”
130 LB RE/HF-A 2 3/4”
130 LB RE-HF 3 1/16"
130 LB HF-B 3 3/8”
130 LB PS 2 3/4”
131 LB RE 3 1/2”
132 LB RE 3 3/32”
133 LB RE 3”
136 LB RE 3 3/32”
136 LB LE VAL 3 1/16”
140 LB RE/140 PS
141 LB AB/ 141 LB RE
152 LB PS 3 3/4”
155 LB PS rail 3 3/8”

(*) to be used with PFA 1 arbour extension and PPL5 Pilot Bit.

6

H

(inches)

2 43/64”

3”

3 3/32”

RAIL

SHOE

MPAF 40 LB ASCE
MPAF 60 LB ASCE
MPAF 80 LB ASCE
MPAF 85 LB ASCE
MPAF 85 LB PRR
MPAF 85 LB PS
MPAF 90 LB ARA-A
MPAF 90 LB ASCE
MPAF 100 LB ARA-A
MPAF 100 LB ARA-B
MPAF 100 LB ASCE
MPAF 100 LB DY
MPAF 100 LB NH
MPAF 100 LB RE
MPAF 100 LB RE-HF
MPAF 100 LB PRR
MPAF 100 LB PS
MPAF 105 LB DY
MPAF 115/119 LB RE
MPAF 122 CB
MPAF 127 LB DYM
MPAF 130 LB RE
MPAF 130 LB RE-HF
MPAF 130 LB HF-B
MPAF 130 LB PS
MPAF 131 LB RE
MPAF 132 LB RE
MPAF 133 LB RE
MPAF 136 LB RE
MPAF 136 LB LVM
MPAF 140 LB RE
MPAF 141 LB AB
MPAF 152 LB PS *
MPAF 155 LB PS *

Cembre

RAIL SHOES DRILLING ON GUARD RAILS

TYPE OF

RAIL

100 LB ARA-B 2 1/4”
112/115/119 LB RE 2 5/8”
115 LB-RE-3132 3 1/32”
132 LB RE 3 9/32”
136 LB RE 3 1/4”

for other types of rail.

H

(inches)

RAIL SHOE

(Using DBG-GR clamp)

MPAF 100 LB ARA-B GR
MPAF 115/119 LB RE GR
MPAF 115 LB-RE-3132
MPAF 132 LB-RE-3932
MPAF 136 LB-RE-314

H

RAIL SHOES DRILLING ON GIRDER RAILS

TYPE OF

RAIL

H

(inches)

128/149 LB 3”
128/149 LB 2 3/4”
149 LB 2 3/4”
GGR 118 2 3/8”
RI60/RI60N 2.87”
NP4A/NP4AM 2.87”
180-105 LB 2.87”

RAIL SHOE

(Using DBG-LY clamp

and 2” depth cutters)

MPAF 128/149 LB GR
MPAF 128/149 LB GR 234
MPAF 149 LB GR 234
MPAF GGR 118
MPAF RI 60 N
MPAF NP4AM
MPAF BA9101

H

3.6) JOINT BAR POSITIONING GAUGES

A

C

Positioning gauges MRF-Y... for drilling joint bar
holes at pre-defi ned distances between rail end
and holes center lines.

B

HOLES DISTANCES

POSITIONING

GAUGE

2 21/32" 7 1/4" 5 1/2"

MRF Y10

3 1/2" 6" 6"
2 21/32" 7 1/4" 5 1/2"

MRF Y11

2 23/32" 6" 7"

MRF Y12

3" 6" -

MRF Y13

2 7/16" 5" -

2 7/16" 7" -

MRF Y14

2 3/8" 7" -

MRF Y15

2 3/4" 6 3/4" 6 3/4"
2 11/16" 5 1/2" 5 1/2"

MRF Y16C

3 1/2" 6" 6"

MRF Y10: suitable for drilling the following rails 100 ARA-B, 115 and 119 LB RE
MRF Y11: suitable for drilling the following rails 100 ARA-B, 105 DL&W
MRF Y12: suitable for drilling the following rails 115, 119, 132, 136, 140 LB RE, 130 and 155 PS
MRF Y13: suitable for drilling the following rails 80, 90 LB ASCE and 100 ARA-A
MRF Y14: suitable for drilling the 85 LB ASCE rail
MRF Y15: suitable for drilling the 130 LB RE and 136 LE.VAL rails
MRF Y: universal positioning gauge for all rail sizes

•

Note: other positioning gauge sizes available upon request.

A B C

3 1/2" 4 3/4" 4 3/4"

3 1/2" 6" 6"

APPENDIX “B”

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.....................................................................................................96,6 dB (A)

Protection of operators against risksof exposure to noise during work.

Cembre

drills type LD-2EY 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 fi nally 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 classifi ed 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,
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

is equal to .................................85,8 dB (A)

pA

is lower than ....................................130 dB (C)

WA

Cembre

2

.

728

3.7) BROACH CUTTERS

These cutters rapidly produce high quality, accurate
holes in a single pass. The automatic lubrocooling
system reduces friction and eliminates heat build up
during the drilling operation. Under standard conditions
a broach cutter can drill 40-50 holes, depending on
the hardness of the rail.

Brush

FIG. 26 – CHANGING THE BRUSHES

APPENDIX “A”

Factors which infl uence 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 effi ciency 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 effi ciency.

– 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 effi cient cutting edges requires a pressure lower than that
applied 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 fl ow rate.

HOLE

DIAME-

TER

(inches)

7/8"

15/16"

1"

1 1/16"

1 1/8"

1 3/16"

1 1/4"

1 5/16"

1 3/8"

1 7/16"

1 1/2"

3/4"
7/8"

15/16“

1“

1 1/16"

1 1/8"

1 3/16“

1 1/4"

1 5/16“

1 3/8"

1 7/16"

1 1/2"
9/16"

3/4"

13/16"

7/8"

15/16"

1"

1 1/8"

BROACH

CUTTER

15128
15130
15132
15234
TSC 1 1/8"
15138
TSC 1 1/4"
TSC 1 5/16"
15144
15146
TSC 1 1/2"
TSC 3/4"
01354
01355
01356
01357
01358
01359
01360
01361
01362
01363
01364
12218
3-12224
3-12226
3-12228
3-12230
3-12232
3-12236

PILOT

BIT

Ref. PPC 2

Ref. PPL 2

3-10528

MAX.

DEPTH OF CUT

(inches)

7/8 "

2 "

3 "

All the broach cutters allow automatic cooling by means of the SR5000 unit supplied with
the drills.

827

3.8) SPECIAL SPIRAL TWIST BITS

Using these bits guarantees optimum performance during the drilling operations. As a
rule, under normal conditions, a spiral bit can drill 70-100 holes, depending on the hard­ness of the rail.

Every 50 hours of operation

13.1.3) Checking the bolts

Check and retighten all bolts.

Diam.

with adapter

APED...

Diam.

without adapter

HOLE

DIAMETER

(inches)

9/32”

3/8”
1/2”
5/8”
3/4”
7/8”
1/2”
3/4”
7/8”

1”
1 1/8”
1 1/4”

For tools of other types, check the dimensional compatibility (particularly the size of the attachment and the length).

SPIRAL

BIT

PE70
PE95 C
PE130
PE160
PE190
PE220
PE130L-AR
PE3/4”-L1-AR
PE7/8”-L1-AR
PE1”-L1-AR
PE1-1/8”-L1-AR
PE1-1/4”-L1-AR

ADAPTER

APED70

APED 3/8 Y

APED 130

APED135/165
without adapter
without adapter

APED 130
without adapter
without adapter
without adapter
without adapter
without adapter

SPACER

included in the APED 70

included in the APED 3/8 Y

included in the APED 130

included in the APED 135/165

DPE
DPE

included in the APED 130

DPE
DPE
DPE
DPE
DPE

ADDITIONAL

ACCESSORIES

not required
not required
not required
not required
not required

not required
TST50 + DBG-AY
TST50 + DBG-AY
TST50 + DBG-AY
TST50 + DBG-AY
TST50 + DBG-AY
TST50 + DBG-AY

13.1.4) Lubrication (Ref. to Figs. 27 and 28)
Lubricate the spindle support housing by means of the appropriate lubricator (18), the
screw (07) of the clamping device with moving arm DBG-Y.

13.1.5) Cleaning of the coolant fi lter (Ref. to Fig. 25)
The coolant system of the drilling machine is provided with anti-impurity fi lter; should an
evident decrease of the fl ow of the lubrocoolant be verifi ed, it could be necessary to clean
it in the following way:
– Using a 14mm key, unscrew the coupling (02).
– Extract the fi lter and clean it carefully.
– Reassemble the fi lter into the coupling (02) as shown in the Fig. 25, fully tighten the
coupling.

anti-impurity fi lter

02

FIG. 25 –
CLEANING OF THE COOLANT FILTER

13.2) ORDINARY MAINTENANCE OF THE MOTOR

3.9) "LR2" LUBROCOOLER CONCENTRA TE, 1 or 5 gallons for optimum

operation of both the broach cutters and the spiral bits.
This product of vegetable origin, to be watered down in the percentage
95% water, 5% oil, will provide a white colour mixture very effective for
the drilling operations resulting in no heating at the rail or the drilling
machines.

3.10) "LR 3" ANTIFREEZE CONCENTRATE of 1 or 5 gallons added
to the lubrocooling mixture with the right percentage will maintain the
lubrocooling mixture fl uid in negative temperature consitions.

LR 2

LR 3

9

Every 50 hours of operation

13.2.1) Changing the brushes (Ref. to Fig. 26)

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.

26

13. MAINTENANCE

4. Type SR5000 COOLANT UNIT (Ref. to Fig. 3)

!

▲

Before servicing or maintenance, stop the motor and disconnect the plug

from the electric source

After fi rst 10 oerating hours, proceed with sump oil change, as follows:

(Ref. to Fig. 28)

– Remove the cap with the magnetic insert (21).
– Remove oil fi ller cap (07).
– Make sure that all the oil comes out by slightly tilting the drill.
– Clean up the cap (21) (see § 13.1.2).
– Reassemble the cap (21).
– Fill the sump with oil to the level indicator (see § 13.1.1) using the oil supplied with the
drilling machine; it will be necessary to use about 4.7 fl oz oil.
– Replace the fi ller cap (07).

13.1) ORDINARY MAINTENANCE OF THE MACHINE (Ref. to Figs. 24 and 28)

Every 20 hours of operation

13.1.1) Topping up oil

With the drill switched off and placed on a fl at 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.

The type SR5000 coolant unit consists of a tank complete with tube and maximum pressure
valve (01), fi tted 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
with a broach cutter, from the position of the guide bit; when drilling with a spiral bit,
delivery and shut-off of the fl uid must be effected manually by operating the tap (02).

The use of the lubrocoolant supplied by
guarantees optimum use of the drilling tools.

Cembre

, in the recommended concentrations,

drilling

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 pres-

sure valve is screwed right down.

●

To fi ll 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

01 – Tank complete with hose
and max. pressure valve
02 – T ap
03 – Quick-coupling
17 – V ent valve
35 – Attachment valve

13.1.2) Removal of metallic residue
from the crankcase

When the drill is positioned as shown
in Fig. 24 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.

FIG. 24 – REMOVAL OF
METALLIC RESIDUE

21

FIG. 3 – COOLANT UNIT

1025

02

03

35

17

● 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 fi t 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 fl uid.

03

35

12. WARNINGS

12.1) Always disconnect the electrical supply when working on the drill to replace cutters,

bits, positioning jigs and/or end pieces for maintenance.

12.2) Regularly check for correct tightening (torque) of the fi xing screws of the drilling
tools and positioning shoes.

12.3) Avoid pressure jolts on the advancing lever during drilling.

12.4) Always make sure that the 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 accelerated wear of the drilling tool 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 tank under pressure and exposed to sunlight for long

periods of time.

12.8) Should the DBG-Y clamping device be removed, make sure that by reassembling
it, the 2 locking screws with 4 washer are fi rmily fastened.

4.1) ARE adaptor

For use with type SR5000 coolant unit. The ARE adaptor is inserted in the quick-coupling
of the tank tube (refer 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 fi xing screws, etc.

ARE adaptor

FIG. 5 – ARE ADAPTOR

11 24

11. STORING THE RAIL DRILL

5. SPINDLE ADVANCE LEVER (Ref. to Fig. 6)

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

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

11.2) Carefully clean the machine, particularly in the spindle area, removing machining
waste (swarf, etc.) and any deposits of lubrocoolant.

11.3) Fully withdraw the spindle.

11.4) Place the rail 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 § 3.3). The DBG-Y moving arm device allows the drill to be housed
and locked in the case. A suitable housing is also provided in this VAL LD for the VAL
MPA box containing the most commonly used accessories.

VAL MPA

The spindle is advanced by moving the lever
(36) (See Fig. 6 a). The lever is fi tted 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

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

LD-2EY

FIG. 23 - STORAGE CASE

VAL LD

23 12

6b - W ith 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).

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

FIG. 7

SELF-LOCKING NUT

6. PREPARING THE RAIL DRILL

9. EXAMPLE OF SPECIAL

RAIL DRILL APPLICATIONS

6.1) Assembling the broachcutters (Ref. to Figs. 8-11)

6.1.1) Insert the pilot 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 suffi cient space is provided to insert the cutter; if necessary rotate
the spindle shaft manually and suffi ciently by inserting the 4 mm male hexagon key in the
appropriate intermediate gear housing (30) 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

18

Short type broach cutter
Maximum drilling thickness: 7/8"

Pilot bit PPC 2

07

– Use on girder rail (Ref. to Fig. 21 a-b, example for 128 GR or GGR 118)

FIG. 21b – Side 2 FIG. 21a – Side 1

DBG-LY over rail clamp

and the specifi c shoes
(combination) allows
the positioning on both
sides of the rails. Use of
2" depth of cut broach
cutters

– Use on running rails (Ref. to Fig. 22)
(narrow passage of the articulated arm)
Drilling by the guard rail DBG-GR
over rail clamp equipped with TDB 1 termination.

Pilot bit PPL 2

Long type broach cutter
Maximum drilling thickness: 2"

FIG. 8 – ASSEMBLING THE CUTTERS

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

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

me accessible and suffi cient space is provided to insert the spiral bit; if necessary rotate
the spindle shaft manually and suffi ciently 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 (71) (see Fig. 11).

13 22

FIG. 22

10. SPECIAL APPLICATIONS FOR

MPAF 85 LB ASCE

= Application developed for narrow chairs

*

1 = For drilling 56 lb aluminium bar manufactered by FOSTER
2 = For drilling 84 lb aluminium bar manufactered by FOSTER
3 = For drilling 84 lb aluminium bar manufactered by PORTER

Cembre RAIL DRILLS

Approach

Start drilling

with discharge of
lubrocoolant

Drilling

6.2.2) Insert into the spindle shaft, the DPE spacer required to activate the coolant system.

If it necessary to use an APE... adaptor, the bit must fi rst be fi tted into the corre
sponding APE adaptor and locked with the appropriate grub screw, then the DPE
spacer inserted.

Note: Adaptors type APED… (e.g. APED 3/8Y) 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 coolant
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.

APE ...

Finish drilling

with removal of swaf and
switching off of
lubrocoolant

FIG. 20 – COOLING DRILLING WITH BROACH CUTTER

8.3) Rail drill fi tted with special spiral bit

Follow the sequence described in § 8.1, taking care to position the rail 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 pilot bit, is kept open at all times by the DPE
spacer fi tted 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.

DPE spacer *

APE or APED adaptor

Spiral bit

DPE

*

18

07

DPE

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

FIG. 9 – ASSEMBLING THE SPIRAL BITS

Bits PE ... (e.g. PE70)

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

FIG.10 – ASSEMBLING THE
BIT-SPACER
UNIT

* use only for APE, not required for APED

FIG. 20a – COOLING DRILLING WITH SPIRAL BIT

71

30

FIG. 11 – MANUAL SPINDLE
ROTATION

1421

7. TYPE LD-2EY RAIL DRILL

The reference LD-2EY relates to the entire LD-2ENY rail drill complete with the clamping
device DBG-Y for clamping it to the rail web and the track fi ttings (Ref. to Fig. 12).

The DBG-Y device consists of:
– Clamping unit.
– Type TDB 6 termination.
– Socket head cap screws M8 x 25 (2 pcs).
– Spring washers (4 pcs).
– Reference pin.

8.1.5) Proceed to drill by initially applying light pressure on the lever (36), increasing
the pressure progressively, avoiding jolts, and fi nally 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.

8.1.6) The pilot bit will enable the lubrocoolant to be discharged throughout the drilling

process.

8.1.7) 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.

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

8.2) Rail drill fi tted with “long” type broach cutter (depth of cut 2").

Follow the sequence described in § 8.1, taking care to position the drill on the rail by
keeping the spindle fully withdrawn.

M 8x25 screws

and spring washers

reference

pin

TDB 6

FIG. 12 – RAIL DRILL LD-2EY

15 20

automatic switch

36

02

39

FIG. 19 – DRILLING

8. DRILLING (Ref. to Figs. 17 - 18 -19)

!

V

Make sure that the mains voltage value corresponds to the value on the machine
rating plate.

!

V

Switch on the cooling system before starting the rail drill (§ 4).

8.1) Rail drill fi tted with “short” type broach cutter (depth of cut 7/8")

The drilling sequence may be started with the drill fi tted with the broach cutter (§ 6.1),
positioning shoe (§ 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 system to male coupling
(35) on the drill.

8.1.2) Open the tap (02) fi tted on the tank tube.

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.

7.1) Assembling of the termination of the DBG-Y device with moving arm for clamping
the drill to the rail web and track fi ttings.

The termination TDB 6 of the DBG-Y device, with moving arm, have been designed for
adaptation to the different operating conditions on the rails and track fi ttings; their assembly
is shown in Fig. 13.

When disassembling the TD termination ensure that, after removing the pivot, the

•

complete assembly is slid away downward without acting on the holding plate.

holding plate

Fig. 17a

<>

8.1.4) Connect the electric plug and press the automatic switch (position "I") (Fig. 18)

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. 17b

36

39

Fig. 17c

FIG. 18

AUTOMATIC SWITCH

FIG. 13 – ASSEMBLY OF THE TERMINATION

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

The DBG-Y clamping device is fi tted 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.

19 16

DBG-Y Clamp

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

35

Drilling machine
front plate

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

7.3.1) The type MPAF .. and MPAU positioning shoes are secured to the front plate (04)
of the drill by means of the two socket head cap screws M 6x16 supplied.

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

The special shape of the positioning shoes, each corresponding to the type of rail, enables
the drill to be positioned quickly, accurately and safely on the element to be drilled.
To position the drilling machine, complete with the clamping termination (§ 7.1) and the
positioning template (§ 7.3) suitable for the type of rail to be drilled, proceed as follows:

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

7.4.2) Bring the moving arm (03) of the clamping device into the fully open position by

means of the handwheel (11).

7.4.3) Place the machine on the rail at the point where the drilling is to be carried out, and
clamp it by tightening the handwheel (11) right down: the positioning shoe will
automatically position the cutter or spiral bit in line with the desired axis; if accurate po-

sitioning relative to the longitudinal axis of the rail is required, use the reference pin (18).

36

11

18

04

reference pin

2 screws M6x16

MPAF...

FIG. 15 – ASSEMBLY OF THE POSITIONING SHOES

MPAU

17

03

07

FIG. 16 – POSITIONING OF THE RAIL DRILL

18