Cembre LD-41PY Operation And Maintenance Manual

08 M 076 U

ENGLISH

Cerfied Quality

Management System

4-CYCLE

HONDA ENGINE

Cerfied Environmental

Management System

RAIL DRILL

TYPE

LD-41PY

Cerfied Occupaonal

Health & Safety

Management System

OPERATION AND MAINTENANCE

MANUAL

1

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.

– During operation keep your hands outside the danger area.

– Always wear protective glasses and work gloves.

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

– Always check combustion engine oil level before operation!

LD-41PNY

basic drill

LD-41PY

(LD–41PN + DBG-Y)
basic drill complete with
railweb clamping device

2

1. RAIL DRILL TYPE LD-41PNY

GENERAL CHARACTERISTICS

The Cembre LD-41PNY drill powered by HONDA 4-cycle engine can be stored and continuously op­erated in full 360° inclination, thanks to the rotary-slinger pumping lubrication system.

– Drilling capacity:...................................................................................................................... Ø 9/40" to 1 9/16"

(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: .............................................................................................................................n° 230 rpm

– Gear sump:

– Recommended oil: ................................................ SHELL SPIRAX S4 TXM

......................................................................................MOBIL SUPER MULTIGRADE 10-30-SAE

– Weight: (LD-41PNY) .....................................................................................................................................35.9 lbs

– Weight: (LD-41PY) ...........................................................................................................................................43 lbs

– Combustion engine (EPA/CARB compliant):

– Type: ............................................................................................4-cycle, overhead camshaft, single cylinder

– Model: .....................................................................................................................................Honda GX35NT STSC

– Operating angle: .............................................................................................................................................infi nite

– Displacement: ....................................................................................................................... 2.18 cu-in (35,8 cm

– Power (SAE J1349): .................................................................................................. 1,0 kW (1,3 HP) / 7000 rpm

– Fuel tank capacity: ............................................................................................................0.16 US gal (0,63 litre)

– Clutch: ................................................................................................centrifugal with automatic intervention

– Start: ..........................................................................................................................................................by rope pull

– Ignition: ............................................................................................................................. transistorized magneto

– Spark plug: .............................................................................................NGK CM5H or CMR5H or equivalents

– Fuel: .............................................................................................unleaded regular grade gasoline ( see § 12)

– Recommended oil: ..................................................................................................SAE 10W-30, API SJ or later

or
or equivalents

3

)

– Acoustic 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
– The level of noise force produced by the machine L

pCPeak

is equal to ................................................................................................................................................101,9 dB (A)

is equal to .............................................................. 96,2 dB (A)

pA

is ......................................................................................< 130 dB (C)

WA

– 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 EN ISO 5349-1/2 and UNI EN 28662-1

Standards, and under operating conditions much more severe

that the weighted root mean square in frequency

is 2,69 m/sec2.

3

of the acceleration the upper limbs are exposed

than those normally found, certify

2. ACCESSORIES SUPPLIED WITH THE 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.

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 onto spindle shaft.

2.5) Socket head cap screws, M6x16

– 4 pcs for securing positioning shoes to front plate.

2.6) Socket head cap screws, M6x25

– 4 pcs for securing special positioning shoes 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 spark plug key
– 1 pc brush

2.8) 3.4 fl oz (100 ml) oil bottle
for gear sump

(Accessories from pos. 2.1 to pos. 2.8 are included
in the “Kit of accessories for LD-41PNY” having
the code 6002682)

2.9) Type SR5000 cooling unit

4

3. OPTIONAL ACCESSORIES (to be ordered separately)

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

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

Always supplied with drilling machine ref. LD-41PY

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

3.1.2) "DBG-GR" device for clamping the drill in correspondance
of guard rail.

Always supplied with drilling machine ref. LD-41PYGR

3.2) "TST50" two stage template (to be used with
specifi c DBG-AY clamping device)
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.

5

3.2) “VAL P24” plastic carrying case for storing the drill complete with the device with moving
arm 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

3.4) “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)

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).

6

3.5.2) "MPAF..." SPECIFIC RAIL SHOES

H

H

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 Cembre for other types of rail.

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

3”
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.

7

H

inch

2 43/64”

3 3/32”

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 *

RAIL

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”

RAIL SHOES DRILLING ON GIRDER RAILS

TYPE OF

RAIL

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”

H

inches

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

inches

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

RAIL SHOE

(Using DBG-GR clamp)

RAIL SHOE

(Using DBG-LY clamp
and 2” depth cutters)

A C

RAIL END

B

3.6) JOINT BAR POSITIONING GAUGES

IL

END

G

ES

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

HOLES DISTANCES (inch)

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

A B C

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

2 23/32" 6" 7"

MRF Y12

3 1/2" 6" 6"

3" 6" -

MRF Y13

2 7/16" 5" -

MRF Y14

2 7/16" 7" -

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.

8

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.

HOLE

DIAMETER

(inch)

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.

9

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.

Diam.

with adapter

APED...

Diam.

without adapter

HOLE

DIAMETER

(inch)

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

TST50 + DBG-AY
TST50 + DBG-AY
TST50 + DBG-AY
TST50 + DBG-AY
TST50 + DBG-AY
TST50 + DBG-AY

3.9) "LR2" LUBROCOOLER CONCENTRATE, 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 eff ective for the drilling operations
resulting in no heating at the rail or the drilling machines.

3.10) "LR3" 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.

ADDITIONAL

ACCESSORIES

not required
not required
not required
not required
not required
not required

LR 2

LR 3

10

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

The type SR5000 coolant unit (01) consists of a tank complete with tube and maximum pressure
valve, 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 drilling with
a broach cutter, by the guide bit; when drilling with a spiral bit, delivery and shut-off of the
fl uid must be eff ected 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 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 – Tank complete with hose
and max. pressure valve
02 – Tap
03 – Quick-coupling
17 – Vent valve
35 – Attachment valve

01

FIG. 3 – COOLANT UNIT

11

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 into the vacant coolant valve seat.

• When temperatures fall below 32° F (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.

36

FIG. 4

4.1) ARE adaptor

03

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 fi xing screws, etc.

35

ARE adaptor

FIG. 5 – ARE ADAPTOR

12

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

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).

36

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 produces
a corresponding advance of the spindle.

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

FIG. 7

13

6. PREPARING THE DRILL

6.1) Assembling broach cutters (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 (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 (18).

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: 1 inch

Pilot bit PP...

07

Pilot bit PPL ...

Long type broach cutter
Maximum drilling thickness: 2 inches

FIG. 8 – ASSEMBLING BROACH CUTTERS

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 acces-

sible 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
(see Fig. 11).

14

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 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 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 ...

18

DPE *

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

07

DPE

* use only for APE, not required for APED

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

FIG. 9 – ASSEMBLING SPIRAL BITS

33

FIG. 11 – MANUAL SPINDLE ROTATION

15

FIG. 10 – ASSEMBLING THE
BIT-SPACER UNIT

71

7. RAIL DRILL TYPE LD-41PY

Ref. LD-41PY consist of the LD-41PNY basic drill (see page 2) complete with the DBG-Y moving arm
device for clamping to the rail web and the track fi ttings (Refer to Fig. 12).

The DBG-Y clamping device consists of:
– Clamping unit
– Type TDB6 standard termination.
– Socket head cap screws M8x25 (2 pcs).
– Spring washers (4 pcs).
– Reference rod.

reference

rod

TDB 6

M 8x25 screws

and spring washers

FIG. 12 – DRILL WITH DBG-Y CLAMPING DEVICE

16

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 diff erent operating conditions on the rails and track fi ttings; their assembly is shown in Fig. 13.

• When disassembling the TDB 6 termination ensure that, after removing the pivot, the complete

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

holding plate

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.

17

DBG-Y Clamping device

FIG. 14 – ASSEMBLY OF DBG-Y
CLAMPING DEVICE

35

Rail drill front plate

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

7.3.1) The type MPAF.. and MPAU positioning shoes are secured to the front plate (22) of the drill
by means of the two socket head cap screws M 6x16 supplied.

reference pin

22

FIG. 15 – ASSEMBLY OF POSITIONING SHOES

MPAF...

MPAU

screws M6x16

18

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 drill, complete with the clamping termination (§ 7.1) and the positioning shoe (§

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 drill 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 positioning relative to the
longitudinal axis of the rail is required, use the reference rod (18).

11

36

FIG. 16 – POSITIONING OF THE DRILL

19

18

03

07

<>

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

Check engine oil level before operation (see § 13.2.4)

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

8.1) Drill fi tted with “short” type broach cutter (for drilling thicknesses of up to 1").

The drilling sequence may be started with the drill fi tted with the broach cutter (§ 6.1), clamping
termination (§ 7.1), 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 unit to the male coupling (35)
on the drill.

8.1.2) Open the tap (02) fi tted on 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
into the initial position (Fig. 17b), which
will enable the travel of the lever (36)
to be used in the most advantageous
way.

Fig. 17a

36

FIG. 17 – DRILLING

Fig. 17b

39

Fig. 17c

20

8.1.4) Start the engine, following instructions on § 11.

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
switch to "OFF" position, and make sure that drilling swarf is removed before recommencing

drilling.

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

8.2) Drill fi tted with “long” type broach cutter (for drilling thicknesses of up to 2").
Follow the sequence described in § 8.1, taking care to position the drill on the rail by keeping the
spindle fully withdrawn.

11

36

02

FIG. 18 – DRILLING

21

35

39

Approach

Start drilling

with discharge of
lubrocoolant

Drilling

Finish drilling

with removal of swarf and
switching off of
lubrocoolant

FIG. 19 – COOLANT DRILLING WITH BROACH CUTTER

8.3) Drill fi tted 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 fi tted on the spigot
of the spiral bit; it must therefore be activated, by opening the tap (02), (see § 4) before starting to
drill, then switched off after drilling by closing the tap.

DPE spacer APE adapter Spiral bit

FIG. 20 – COOLANT DRILLING WITH SPIRAL BIT

22

9. EXAMPLE OF SPECIAL RAIL DRILL APPLICATIONS

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

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)

FIG. 21b – Side 2 FIG. 21a – Side 1

DBG-GR over rail clamp equipped with TDB1 termination

10. SPECIAL APPLICATIONS FOR Cembre RAIL DRILLS

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

23

FIG. 22

11. START ENGINE

Before starting the engine, ensure that:

- the spindle shaft is fully retracted.

- the accelerator control lever is positioned at the low
speed position.

11.1) Set the engine “ON/OFF” switch to the “ON” position (Fig. a).

11.2) Set the choke lever to the CLOSED position;

when engine is warm or in the case of high ambient temperatures,
this lever may require setting to the OPEN position (Fig. b).

11.3) Keeping the accelerator control lever at the low speed
position, press the priming bulb repeatedly until fuel can be seen
in the clear-plastic fuel-return tube (Fig. c).

11.4) Pull the starter grip lightly until resistance is felt, then pull
briskly (Fig. d). Return the starter grip gently.

Do not pull the rope out all the way.
Do not allow the starter grip to snap back against the engine,
return it gently to prevent damage to the starter.

11.5) If the choke lever was moved to the CLOSED position

to start the engine, gradually move it to the OPEN position as the
engine warms up (Fig. e).

11.6) Keep the engine “warming up” for at least 3 minutes before
starting any actual drilling.

11.7) To stop the engine, set the accelerator lever at the low
speed position and allow the engine to run at low speed for 2 or
3 minutes before stopping. Set the “ON/OFF” switch to the “OFF”
position.

a)

b)

c)

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

d)

24

e)

12. CHECK FUEL

E

WARNING

- Gasoline is extremely fl ammable and explosive.

- Stop engine before refueling.
 DO NOT SMOKE.

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

- Stop engine and allow 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 the engine in an enclosed area.

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

- The engine becomes hot during operation.

The LD-41PY drilling machine features a 4-CYCLE gasoline engine run on unleaded regular gas­oline only.

Pump octane rating 86 or higher.
For refuel proceed as follow:
– Check the fuel level by looking through the translucent fuel tank.
– Stop the engine and open the fuel cap, if the engine has been running, allow it to cool.
– Refi ll fuel to the upper level.
– Do not overfi ll with fuel.
– When fi lling the fuel tank, always use the fuel fi lter.
– Wipe off any spilled fuel before starting the engine.

FUEL FILLER CAP

TAPPO SERBATOIO

25

MAXIMUM

LIVELLO SUPERIOR

FUEL LEVE

L

FUEL
FILLER CAP

13. STORAGE

26

foldingi

ng arm dev

ice alloo

vided in the plastic cas

efor

c

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

13.1) 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).

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

13.3) Fully withdraw the spindle.

13.4) 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 P24 plastic case or VAL P24-CS
(variant with folding handle and wheels, see Fig. 24a) designed for this purpose (see § 3.2). The
DBG-Y 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

FIG. 23 - STORAGE CASE

PLASTIC CASE

26

14. MAINTENANCE

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

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

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

(Ref. to Figs. 24 and 24a)

– Remove the cap with the magnetic insert (28).
– Remove the oil fi ller cap (07).
– Make sure that all the oil comes out by tilting slightly the drilling
machine in order to make the operation easier.
– Clean the cap (28) (see § 14.1.2).
– Reassemble the cap.
– Fill the oil sump to the level indicator (see § 14.1.1)
using the oil supplied with the drilling machine; it will be
necessary to use about 100 ml oil.
– Replace the oil fi ller cap (07).

07

Ensure that disposal of used oil is in

accordance with current legislation.

14.1) ORDINARY MAINTENANCE OF THE DRILL

Every 20 hours of operation

14.1.1) Topping up oil (Ref. to Figs. 24 and 24a)

With the drill switched off and placed on a fl at surface, check
the oil level in the crankcase by looking through the transparent
inspection cover (19).
The level must be approximately half way up the cover; if the
level is low, top up the oil by unscrewing the cap (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. 24

FIG. 24a

27

19

28

14.1.2) Removal of metal residues from the crankcase

When the drill is positioned as shown in Fig. 25unscrew
the cap with magnetic insert (28) on which any metal
residues present in the oil will have collected. Carefully
clean the magnetic insert with a clean cloth and screw
it back into the appropriate housing.

FIG. 25 – REMOVAL OF

METAL RESIDUES

Every 50 hours of operating

14.1.3) Checking of screws.

– Check and re-tighten all screws where necessary.

14.1.4) Lubrication (Ref. to Figs. 32 and 33)
– Lubricate the spindle support housing by means of the appropriate lubricator (25), the screw of
the DBG-Y clamping device.

14.1.5) Cleaning of coolant fi lter (Ref. to Fig. 26)
The coolant system of the drilling machine is provided with anti-impurity fi lter; should a decrease
of the fl ow of the lubrocoolant be noticed, it may 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. 26, fully tighten the coupling.

anti-impurity fi lter

28

02

FIG. 26 –
CLEANING OF COOLANT FILTER

28

14.2 ORDINARY MAINTENANCE OF THE COMBUSTION ENGINE

Periodic inspections are essential for the proper functioning of the engine;
refer to "HONDA" manual provided with the machine for the safe use of the
engine and for further requested maintenance operations.

Every 100 hours of operation

14.2.1) Fuel fi lter cleaning (Ref. to Fig. 27)

– Check that the engine oil fi ller cap is tightened securely.
– Remove the fuel fi ller cap, and drain the fuel into an approved gasoline container by tipping the
engine toward the fuel fi ller neck.
– Pull the fuel fi lter out through the fuel fi ller neck by hooking
the black fuel tube with a piece of wire, such as a partly
straightened paper clip.
– Inspect the fuel fi lter. If the fuel fi lter is dirty, wash it gently
with nonfl ammable or high fl ash point solvent. If the fuel
fi lter is excessively dirty, replace it.
– Remove water and dirt from inside the fuel tank by rinsing
it out with non-fl ammable or high fl ash point solvent.
– Insert the fuel fi lter into the fuel tank and tighten the fuel
fi ller cap securely.

Improper use of solvents can result in fi re or explosion.

fuel fi lter

FIG. 27 – FUEL FILTER CLEANING

Every 3 months or 25 hours of operation

14.2.2) Air fi lter cleaning (Ref. to Fig. 28)

– Press the latch tab (A) on the top of the air cleaner cover
and remove the cover.
– Clean the fi lter element in warm soapy water, rinse and
allow to dr y thoroughly, or clean in non fl ammable solvent
and allow to dry.
– Dip the fi lter element in clean engine oil, then squeeze
out all excess oil.
– Wipe dirt from the air cleaner body and cover, using a
moist rag. Be careful to prevent dirt from entering the
carburettor.
– Reinstall the fi lter element and air cleaner cover.
Always replace damaged fi lter elements.

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

29

A

fi lter element

FIG. 28 – AIR FILTER CLEANING

Every year or 100 hours of operation

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

– Using a 4 mm allen key remove the fi xing screw on the top of the red cover.
– Disconnect the spark plug wire lead and remove the spark plug with the key supplied.
Inspect the spark plug. Replace it if damaged or badly fouled, if the sealing washer is in poor
condition, or if the electrode is worn. Measure the spark plug electrode gap, correct the gap if
necessary by carefully bending the side electrode.
The gap should be: 0.60-0.70 mm (0.024-0.028 in).
– Install the spark plug carefully, by hand, to avoid
crossthreading.
– When installing a new spark plug, tighten 1/2 turn
with the key to compress the washer.
When reinstalling the original spark plug, tighten
1/8-1/4 turn with the key to compress the washer.

A loose spark plug can overheat and damage

spark plug

the engine. Overtightening the spark plug can
damage the threads in the cylinder head.

– Attach the spark plug cap to the spark plug.
Install the top cover, and tighten the fi xing screw.
– In case of plug replacement, use type NGK, CM5H,

CMR5H or equivalents.

FIG. 29 – SPARK PLUG CLEANING

13.2.4) Check engine oil (each use) (Ref. to Fig. 30)

Before checking or refi lling engine oil, be sure the machine is located on a stable, level surface and
stopped.
– Remove the oil fi ller cap/dipstick and wipe it clean.
– Insert the oil fi ller cap/dipstick without screwing it into the oil fi ller neck, then remove it to check
the oil level shown on the dipstick.
If the oil level is near or below the lower limit mark on the dipstick, fi ll to the bottom edge of the
oil fi ll hole with the recommended oil (see § 1).
– Change oil if it is contaminated.
– Wipe off any spilled oil before starting the engine.
– Reinstall the oil fi ller cap/dipstick and tighten securely.

LIMITE

SUPERIORE

MITE

UPPER LIMIT

RIORE

UPPER LIMIT

OIL FILLER CAP/DIPSTICK

FIG. 30 – CHECK ENGINE OIL

LOWER LIMIT

OIL FILL HOLE
(bottom edge)

30

14.2.5) Engine oil change (Ref. to Figs. 30 and 31)

Initial oil change: fi rst month or after 10 hours of operation

Thereafter: every 6 months or 50 hours of operation

– Drain the used oil when the engine is warm. Warm oil drains quickly and completely.
– Check that the fuel fi ller cap is tightened securely.
– Place a suitable container below the engine to catch the used oil.
– Remove the oil fi ller cap/dipstick and drain the oil into the container by tipping the machine
toward the oil fi ller neck.
Some oil will remain in the engine after draining, when refi lling with fresh oil, start with less than

2.7 US oz (80 ml).
– With the engine in a level position, fi ll to the bottom edge of the oil fi ll hole (Ref. to Fig. 30 and

31) with the recommended oil (see § 1).

– MAX OIL CAPACITY: 3.4 US oz (100 ml).

Always use the best grade and clean oil.
Contaminated oil, poor quality oil and shortage of oil
cause damage to engine or shorten the engine life.

Ensure that disposal of used oil is in

oil fi ller
cap/dipstick

accordance with current legislation.

14.2.6) Checking of screws.

FIG. 31 – ENGINE OIL CHANGE

– Check and re-tighten all screws where necessary.

14.3 SPECIAL SERVICING.

14.3.1) Storing the drilling machine 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

3

of oil into the cylinder.
– Repeatedly pull gently on the starting rope so that dispersion of oil in the cylinder is achieved
and reinstall the spark plug.
– Using a clean cloth soaked with motor oil, 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.

31

11

10

09

08
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. 32 – LD-41PNY DRILL ASSEMBLY

32

12
13

14
15

16
17

18
19

20
21
22
23

24
25

26
27

28

33

6001209
6900060
6001731
6001198
6002607
6002602
6001397
6340160

6001195

6900346

6001211

Code N°

Magnetic cap

28

M 4x8 screw

27

Cooling connection guard

26

Lubricator

25

Front plate

24

Drilling spindle

23

Complete air valve

22

M 8 x 10 grub screw

21

-

-

-

Fuel fi lter

20

Level gauge

19

Fuel tank

18

Handle Screw

17

Fuel tank cap

16

ON/OFF Switch

15

Item

Description

1
2
1
1
1
1
1
1
1
1
1
2
1
1

Qty

-

-

6003476

­6380330
6002613
6001166
6003034
6490050
6001940
6360480
6001176
6001428
6001489

Code N°

Engine

13

Air fi lter element

12

Spark plug

11

Handle

10

Complete handgrip

09

Accelerator lever

08

Cap

07

Carriage handle

06

Spindle advancing lever

05

O-ring

04

Lever release pawl

03
02

Complete cooling connection

01

Body

Item QtyDescription

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

Starting handgrip

14

14

17

12

11

13

16

01

02

03

04

05

08

09

07

25

20

23

21

22

24

29

30

10

06

26

27

28

1111122442111211121111111

Clamping support left shoulder

Clamping support right shoulder

M 8 x 10 grub screw

Clamping handle knob

Blocking lever

Compl. blocking screw

6380310

6001150

6001658

Thickness

6001659

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

30292827262524232221201716131211100908070605040302

6001154

6700524

6040421

6001155

6001156

6760378

6340612

6900314

6650144

6900348

6760222

6140082

6001775

6001751

6001756

6001754

6340160

Adjusting bush

Cup spring

ø2,5 x 16 Split pin

Clamping support

6001152

6520422

6140085

6001145

1

Qty

Description

Drilling reference rod

01

Item

6001281

Code N°

FIG. 33 – “DBG-Y” RAIL WEB CLAMPING DEVICE

34

15. WARNINGS

15.1) Regularly check for correct tightening (torque) of the fi xing screws of the drilling tools and

positioning templates.

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

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

hole.

15.4) Incomplete clamping of the drill on the rail to be drilled may lead to the breakage or accel­ erated wear of the drilling tool and damage to the spindle shaft bearings.

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

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

15.7) Should the DBG-Y clamping device be removed, make sure that by reassembling it, the two
locking screws are fi rmly fastened.

16. 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 Certifi cate supplied by Cembre together with the tool or fi ll in and attach
the form available in the “ASSISTANCE” section of the Cembre website.

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 clamping and correct assembly of the drilling tool.
– 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 tool with the material to be drilled; bear in mind that
the faster the hole is made, the greater the effi ciency.

– Observance of these basic rules:

1) Commence drilling by exerting light pressure on the advancing lever, progressively inc­ reasing and then relaxing it when the tool 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 tool.

3) Remember that a tool with effi cient cutting edges requires a lower application pressure than
one that has already made a certain number of holes.

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.

35

Cembre S.p.A.

Via Serenissima, 9
25135 Brescia (Italia)
Telefono: 030 36921
Telefax: 030 3365766
E-mail: [e-mail]
www.cembre.it

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: [e-mail]
www.cembre.es

www.cembre.com

Cembre Ltd.

Dunton Park
Kingsbury Road, Curdworth - Sutton Coldeld
West Midlands B76 9EB (Great Britain)
Tel.: [phone] - Fax: [phone]
E-mail: [e-mail]
www.cembre.co.uk

Cembre GmbH

Heidemannstraße 166
80939 München (Deutschland)
Telefon: [phone]
Telefax: 089 35806777
E-mail: [e-mail]
www.cembre.de

Cembre Inc.

Raritan Center Business Park
181 Fieldcrest Avenue
Edison, New Jersey 08837 (USA)
Tel.: [phone] - Fax: [phone]
E-mail: [e-mail]
www.cembreinc.com

Cembre S.a.r.l.

22 Avenue Ferdinand de Lesseps
91420 Morangis (France)
Tél.: [phone] - Fax: [phone]
CS 92014 – 91423 Morangis Cédex
E-mail: [e-mail]
www.cembre.fr

36

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 specifi cations in this manual without prior notice.

cod. 6261198