Cembre LD-2EYGR Specifications

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Cembre LD-2EYGR Specifications | Manualzz

07 M 053 U

ENGLISH

Certified Quality

Management System

Certified Environmental

Management System

Certified Occupational

Health & Safety

Management System

RAIL DRILL

TYPE

LD-2EY

PATENTED

www.cembre.com

Cembre S.p.A.

Via Serenissima, 9

25135 Brescia (Italia)

Telefono: 030 36921

Telefax: 030 3365766

E-mail: [email protected]

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: [email protected]

www.cembre.es

Cembre Ltd.

Dunton Park

Kingsbury Road, Curdworth - Sutton Coldfield

West Midlands B76 9EB (Great Britain)

Tel.: 01675 470440 - Fax: 01675 470220

E-mail: [email protected]

www.cembre.co.uk

Cembre AS

Fossnes Senter

N-3160 Stokke (Norway)

Phone: (47) 33361765

Telefax: (47) 33361766

E-mail: [email protected]

www.cembre.no

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

B.P. 37 - 91421 Morangis Cédex

E-mail: [email protected]

www.cembre.fr

Cembre GmbH

Heidemannstraße 166

80939 München (Deutschland)

Telefon: 089/3580676

Telefax: 089/35806777

E-mail: [email protected]

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: [email protected]

www.cembreinc.com

OPERATION 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 page

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

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

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

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

14. Return to Cembre for overhaul ..........................................................................29

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

Appendix “B” ..............................................................................................................28

1 34

NOTES

33

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

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

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

– power rating: ...................................................................................................... 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.

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

– Weight: with “DBG-Y” clamping device .............................................................. 38 lbs

– Recommended gear sump oil: MOBIL DTE OIL LIGHT

ESSO TERESSO 32

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

or or equivalent

2

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.

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)

3

12

13

14

15

16

17

18

09

10

11

19

20

21

22

-

6001209

6900060

6001731

6001198

6001397

6001144

6001146

6340160

6001195

6001818

Code No

22

21

20

19

18

17

16

15

14

13

12

Item

Electric plug

Magnetic cap

Screw M 4x8

Guard

Lubricator

Complete air valve

Front plate

Drilling spindle

M 8x10 grub screw

Transparent inspection cover

Automatic switch

Description

1

1

2

1

1

1

1

1

1

1

2

Qty

6001368

6001422

6380316

6380330

6001210

6001238

6001262

6360480

6001176

6001428

6001997

Code No

11

10

09

08

07

06

05

04

03

02

01

Item

Electric motor

Brush

Handle

Handgrip

Cap

Carrying handle

Spindle advance lever

O-ring

Lever release pawl

Complete coolant connection

Complete body

Description

1

1

1

1

1

1

2

1

1

1

1

Qty

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.

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

08

07

06

05

04

03

02

01

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

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

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.

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)

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

15. RETURN TO Cembre FOR OVERHAUL

In the case of a breakdown contact our Area Agent who will advise you on the problem and give you the necessary instructions on how to dispatch the tool to our nearest service

Centre; if possible, attach a copy of the Test 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 Cembre for other types of rail.

RAIL SHOES DRILLING ON RUNNING RAILS

TYPE OF

RAIL

40 LB ASCE

60 LB ASCE

80 LB ASCE

85 LB ASCE

85 LB PRR

85 LB PS

H

(inches)

3 1/16"

3 1/16"

2 3/16”

2 17/64”

2 1/16”

2 15/64”

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

90 LB ARA-A

90 LB ASCE

2 9/16”

2 45/128” MPAF 90 LB ASCE

100 LB ARA-A 2 3/4”

MPAF 90 LB ARA-A

MPAF 100 LB ARA-A

100 LB ARA-B 2 65/128” MPAF 100 LB ARA-B

100 LB ASCE

100 LB DY

2 65/128”

2 5/8”

100 LB NYNH&H 2 39/64”

MPAF 100 LB ASCE

MPAF 100 LB DY

MPAF 100 LB NH

100 LB RE 2 45/64”

100 LB RE-HF 2 45/64”

100 LB PRR

100 LB PS

2 9/32”

2 31/64”

MPAF 100 LB RE

MPAF 100 LB RE-HF

MPAF 100 LB PRR

MPAF 100 LB PS

105 LB DY/110 LB RE 2 43/64”

112/115/119 LB RE 2 7/8”

122 CB

127 LB DY

2 7/8”

3 1/8”

130 LB RE/HF-A 2 3/4”

130 LB RE-HF 3 1/16"

130 LB HF-B

130 LB PS

3 3/8”

2 3/4”

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

131 LB RE

132 LB RE

133 LB RE

136 LB RE

3 1/2”

3 3/32”

3”

3 3/32”

MPAF 131 LB RE

MPAF 132 LB RE

MPAF 133 LB RE

MPAF 136 LB RE

136 LB LE VAL 3 1/16”

140 LB RE/140 PS 3”

141 LB AB/ 141 LB RE 3 3/32”

152 LB PS 3 3/4”

MPAF 136 LB LVM

MPAF 140 LB RE

MPAF 141 LB AB

MPAF 152 LB PS *

155 LB PS rail 3 3/8” MPAF 155 LB PS *

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

6

RAIL SHOES DRILLING ON GUARD RAILS

TYPE OF

RAIL

H

(inches)

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 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

RAIL SHOES DRILLING ON GIRDER RAILS

TYPE OF

RAIL

H

(inches)

RAIL SHOE

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

128/149 LB

128/149 LB

149 LB

GGR 118

3”

2 3/4”

2 3/4”

2 3/8”

MPAF 128/149 LB GR

MPAF 128/149 LB GR 234

MPAF 149 LB GR 234

MPAF GGR 118

RI60/RI60N MPAF RI 60 N

NP4A/NP4AM 2.87”

180-105 LB 2.87”

MPAF NP4AM

MPAF BA9101

3.6) JOINT BAR POSITIONING GAUGES

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

A B C

HOLES DISTANCES

POSITIONING

GAUGE

A B

MRF Y10

MRF Y11

MRF Y12

MRF Y13

MRF Y14

MRF Y15

MRF Y16C

2 21/32"

3 1/2"

2 21/32"

3 1/2"

2 23/32"

3 1/2"

3"

2 7/16"

2 7/16"

2 3/8"

2 3/4"

2 11/16"

3 1/2"

7 1/4"

6"

7 1/4"

4 3/4"

6"

6"

6"

5"

7"

7"

6 3/4"

5 1/2"

6"

C

-

-

6 3/4"

5 1/2"

6"

7"

6"

-

-

5 1/2"

6"

5 1/2"

4 3/4"

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.

7

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 pA

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

– The maximum value of instantaneous weighted noise

pressure C at the working place L pCPeak is lower than ....................................130 dB (C)

– The level of noise force produced by the machine L

WA

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, 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 2 .

28

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, progres- sively 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.

27

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.

BROACH

CUTTER

01358

01359

01360

01361

01362

01363

01364

12218

3-12224

3-12226

3-12228

3-12230

3-12232

3-12236

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 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"

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“

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.

8

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.

with adapter

APED...

without adapter

HOLE

DIAMETER

(inches)

SPIRAL

BIT

ADAPTER SPACER

ADDITIONAL

ACCESSORIES

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”

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

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 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 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

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

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 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

13.1.3) Checking the bolts

Check and retighten all bolts.

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

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

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.

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.

21

FIG. 24 – REMOVAL OF

METALLIC RESIDUE

25

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

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 drilling 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 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 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 – Tap

03 – Quick-coupling

17 – Vent valve

35 – Attachment valve

FIG. 3 – COOLANT UNIT

10

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

– 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

35

03

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

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.

24

11. STORING THE RAIL DRILL

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.

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).

FIG. 6

6a - Moving the lever (36) towards the operator;

corresponding advance of the spindle.

VAL MPA

LD-2EY

FIG. 23 - STORAGE CASE

VAL LD

23

6b - With the release pawl (39) pressed, the lever is

released from its hub and can repeat the previous

travel without the spindle moving.

6c - With the hub released, moving the lever

towards the operator causes a corre-

sponding advance of the spindle.

FIG. 7

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).

SELF-LOCKING NUT

12

6. PREPARING THE RAIL DRILL

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.

07

Engaging dogs

18

Short type broach cutter

Maximum drilling thickness: 7/8"

Pilot bit PPC 2

9. EXAMPLE OF SPECIAL

RAIL DRILL APPLICATIONS

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

FIG. 21a – Side 1 FIG. 21b – Side 2

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.

FIG. 22

10. SPECIAL APPLICATIONS FOR Cembre RAIL DRILLS

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 become 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

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

22

Approach

Start drilling with discharge of lubrocoolant

Drilling

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.

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

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 ...

DPE

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

18

07

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

DPE

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

FIG. 9 – ASSEMBLING THE SPIRAL BITS

FIG.10 – ASSEMBLING THE

BIT-SPACER

UNIT

DPE spacer * APE or APED adaptor Spiral bit

* use only for APE, not required for APED

FIG. 20a – COOLING DRILLING WITH SPIRAL BIT

21

FIG. 11 – MANUAL SPINDLE

ROTATION

14

30

71

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.

36

02 reference pin

TDB 6

M 8x25 screws and spring washers

FIG. 12 – RAIL DRILL LD-2EY

15

FIG. 19 – DRILLING

20

39 automatic switch

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

V

Make sure that the mains voltage value corresponds to the value on the machine

V

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.

Fig. 17a Fig. 17b

36

<>

39

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. 18

AUTOMATIC SWITCH

19

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. 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.

16

DBG-Y Clamp

FIG. 14 – ASSEMBLY OF THE

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

36

11

18

03

04

MPAU reference pin

2 screws M6x16

MPAF...

FIG. 15 – ASSEMBLY OF THE POSITIONING SHOES

17

07

FIG. 16 – POSITIONING OF THE RAIL DRILL

18

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