Cembre LD-41P Rail drilling machines Manual

Cembre LD-41P Rail drilling machines Manual
15 M 068 E
ENGLISH
HO 4ND STR
A OK
EN E
GI
NE
Certified Quality
Management System
Certified Environmental
Management System
Certified Occupational
Health & Safety
Management System
RAIL DRILL
TYPE
LD-41P
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.
– STOP THE ENGINE when servicing the drill: before removing the broach cutters, spiral bits, positioning templates etc.
– During operation keep hands away from the danger zone.
– Always wear protective glasses and work gloves.
– Avoid wearing clothes which may present a risk to personal safety.
LD-41PN
basic drill
LD-41P
(LD–41PN + DBG-F2)
basic drill complete with
railweb clamping device
2
1. GENERAL CHARACTERISTICS
LD-41PN
Drilling capacity (*):
Ø 7 ÷ 40 mm
Speed without load:
230 rpm
Weight:
16,3 kg
Weight with DBG-F2:
19,5 kg
(*) with broach cutters on thicknesses up to 50 mm
with special spiral bits on thicknesses up to 45 mm
Gear sump
Recommended oil:
Combustion engine:
Type:
Model:
Displacement:
Power (SAE J1349):
Fuel tank capacity:
Clutch:
Start:
Ignition:
Spark plug:
Fuel:
Recommended oil:
Operating angle:
Emissions:
SHELL SPIRAX S4 TXM or
MOBIL SUPERMULTIGRADE 10-30-SAE or equivalents
4-stroke, overhead camshaft, single cylinder
Honda GX35NT STSC
35,8 cm3
1,0 kW (1,3 HP) / 7000 rpm
0,63 litres
centrifugal with automatic intervention
by rope pull
transistorized magneto
NGK CM5H or CMR5H or equivalents
unleaded regular grade petrol (see § 10)
SAE 10W-30, API SJ or later
infinite, can be stored and continuously operated in full 360°
inclination, thanks to the rotary-slinger pumping lubrication system.
according to “Phase 2”
European Directives 97/68/EC, 2001/63/EC and 2002/88/EC
Acoustic Noise (Directive 2006/42/EC, annexe 1, point 1.7.4.2 letter u)
– The weighted continuous acoustic pressure level equivalent
A at the work place LpA is equal to......................................................................................... 96,2 dB (A)
– The maximum value of the weighted acoustic displacement
pressure C at the work place LpCPeak is ............................................................................... < 130 dB (C)
– The acoustic power level emitted by the machine
LWA is equal to..............................................................................................................................101,9 dB (A)
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 than those
normally found, certify that the weighted root mean square in frequency of the acceleration the upper limbs are exposed is 2,69 m/sec2 max.
3
2. ACCESSORIES SUPPLIED WITH THE DRILL
2.1) Guide bits for controlling the coolant system:
for broach cutters suitable for drilling thicknesses up to 25 mm
– 1 pc PP 1, diameter 7 mm
– 1 pc PP 2, diameter 8 mm
for broach cutters suitable for drilling thicknesses up to 50 mm
– 1 pc PPL 1, diameter 7 mm
– 1 pc PPL 2, diameter 8 mm
2.2) Spacer, type DPE, for controlling the coolant system, for special
spiral bits, diam. 7 ÷ 27,5 mm.
2.3) Adaptor, type ARE, for external 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 templates to front plate.
2.6) Socket head cap screws, M6x25
– 4 pcs for securing special positioning templates 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 for remove the drilling swarf
2.8) 100 ml oil bottle for gear sump.
Parts 2.1 to 2.8 are included in the "LD-41PN ACCESSORIES KIT "
code 6002604.
2.9) Type SR5000 cooling unit.
4
3. ACCESSORIES TO BE ORDERED SEPARATELY
3.1) DBG-F2 device (*) with moving arm for clamping the
drill to the rail web and track fittings, complete with the
following end pieces:
– TDB 6: standard end piece for rails and stock rails.
– TDB 1: for switch blades and compound frogs.
– TDB 3: for repairing (adjusting) existing holes on rails
for subsequent application of electrical connections and
for additional special applications.
(*) Always supplied with type LD-41P drill.
TDB 1
TDB 7
TDB 6
TDB 3
3.1.1) DBG-LF2 device with moving arm complete with
TDB 7 end piece for clamping the drill to girder rails and
for additional special applications.
3.2) “VAL P24” plastic carrying case for storing the drill complete with the DBG-F2 device and
accessories.
Also available VAL P24-CS plastic carrying case with folding handle and wheels.
3.2.1) “VAL LD-L” metal case for storing the drill complete with the DBG-LF2 device, and
VAL MPA tool case.
VAL P24-CS
5
VAL LD-L
3.3) Templates for positioning the drill on rails and stock rails
to enable drilling to be carried out according to the provisions of
railway board standards:
– MPAF UIC54 on DRILLING AXIS of UIC 54 rail
– MPAF UIC60 on DRILLING AXIS of UIC 60 rail
– MPAFN UIC60 on DRILLING/NEUTRAL AXIS of UIC 60 rail
• Note: Contact Cembre for selection of specific application
accessories.
3.4) MPAU universal positioning template suitable both for repairing existing holes on various fittings, and for drilling disused
rails.
3.5) SPA positioning plates for drilling rail heads with a centreto-centre distance established in the Railway board standards,
without the need for marking out; for use in conjunction with
MPAF... positioning templates.
3.6) MRF clamp to be applied as a reference to the head of rails
for use, in conjunction with SPA... positioning plates, for in-line
drilling of rail heads, with established centre-to-centre distance.
3.7) VAL MPA tool case suitable for storing the accessories
indicated in 3.3 - 3.6, and the drilling tools.
6
3.8) Broach cutters
BROACH CUTTERS FOR RAILS IN STEEL QUALITY 700-900-1100 (UIC 860.0)
Ø
mm
13
13,5
14
16
17
17,5
18
19
20
21
22
23
24
25
26
27
27,5
28
29
30
31
32
33
SHORT RANGE
Broach cutter
CY130
CY135
CY160
CY170
CY175
CY180
CY190
CY200
CY210
CY220
CY230
CY240
CY250
CY260
CY270
CY275
CY280
CY290
CY300
CY310
CY320
CY330
Guide bit
Ref. PP 1
Ref. PP 2
MAX DRILLING THICKNESS
25 mm
LONG RANGE (L max = 88mm)
Broach cutter
CY140L
CY160L
CY170L
Guide bit
Ref. PPL 1
Ref. PPL 2
CY180L
CY190L
CY200L
CY210L
CY220L
CY230L
CY240L
CY250L
CY260L
CY270L
CY280L
CY290L
CY300L
CY320L
CY330L
MAX DRILLING THICKNESS
50 mm
Contact Cembre for other types of broach cutters.
Broach cutters resharpening must be carried out in compliance with appropriate modes of operation which
allow the best result.
7
3.9) Spiral bits
h
APED...
ø
FIG. 1
APE...
L max
L max
ø
FIG. 2
PE 70
PE 71
PE 80
PE 85
PE 90
PE 95
PE 100
PE 110
PE 120
PE 130AR
PE 135AR
L
h
max mm
mm
76
72
Adaptor
ref.
1,2 APED 70
APED 80
76
1,4 APE 90
APE 95
APE 100
APE 110
APE 120
1,6
APED 130
APED 135/165
Ø
mm
14
16
17
17,5
18
19
2
21
22
24
27,5
1
Spiral Bit
ref.
(*)
PE 140
PE 160
PE 170AR
PE 175
PE 180
PE 190AR
PE 210AR
PE 220
PE 240AR
PE 275AR
L
h
max mm
mm
76
Adaptor
ref.
special high quality spiral bit.
7
7,1
8
8,5
9
1 9,5
10
11
12
13
13,5
Spiral Bit
ref.
(*)
1,6 APED 135/165
88
85
(*) PE... AR:
Ø
mm
Figure
Figure
SPECIAL SPIRAL BITS FOR RAILS IN STEEL QUALITY 700 - 900 - 1100 (UIC 860.0)
88
– The special spiral bits in the PE range allow automatic cooling by means of the SR5000 unit supplied with
the drilling machine.
– All spiral bits in the PE range allow drilling of thicknesses up to 45 mm.
The drilling tools indicated in the table guarantee optimum results. For tools of other types, check the dimensional compatibility (particularly the size of the attachment and the length).
3.10) LR2 BIODEGRADABLE LUBROCOOLANT
3 litre container to be used in a 5-10 % solution, for optimum operation of both broach cutters
and spiral bits.
3.11) LR3 ANTIFREEZE CONCENTRATE
3 litre added to the lubrocoolant mixture in the right concentration will
maintain the lubrocoolant mixture fluid in negative temperature conditions.
3l
8
4. COOLANT UNIT TYPE SR5000
The type SR5000 coolant unit consists of a tank complete with tube and maximum pressure
valve (01), fitted with a pump device for pressurisation, which must be connected to the attachment (35) on the drill by means of its quick-coupling (03).
The delivery and shut-off of the lubrocoolant are controlled automatically, when drilling with
a broach cutter, by the guide bit; when drilling with a spiral bit, delivery and shut-off of the
fluid must be effected manually by operating the tap (02). The use of the lubrocoolant supplied
by Cembre, in the recommended concentrations, guarantees optimum use of the drilling tools.
Consumption of the lubrocoolant depends both on the variable degree of opening of the tap
(02) and the inner pressure of the tank: it is therefore advisable to open the tap a little when the
tank is at maximum pressure, while it must be fully opened when the pressure in the tank is low.
When using the coolant system, pay careful attention to the instructions on the tank label.
WARNING:
• When the tank is not under pressure, check that the bush on the maximum pressure valve is
screwed right down.
• To fill tank with lubrocoolant, turn handle anticlockwise approximately 2 turns to release handle
locking mechanism. Remove handle/piston assembly from tank.
Detail of the
max pressure valve
01 –
02 –
03 –
17 –
35 –
Tank complete with hose
and max. pressure valve
Tap
Quick-coupling
Vent valve
Attachment valve
01
02
FIG. 3 – COOLANT UNIT
9
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 fit into the vent valve seat.
– Fit the vent valve into the vacant coolant valve seat.
 When temperatures fall below 0° C the lubrocoolant
may freeze which could cause damage to the seals
contained in the drill coolant system.
It is therefore advisable, when storing the drilling
machine, to empty the lubrocoolant system
completely.
Proceed as follows (Fig. 4):
– Disconnect the quick coupling (03) from the
coolant attachment (35) on the drilling machine.
– Tilt the machine so that the coolant attachment is
at its lowest point - allowing for natural drainage.
– Operate the advancing lever (36) to advance and retract
the drilling spindle.
– Gently shake the machine to expel all fluid.
36
FIG. 4
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 (Ref. to Fig. 5), it may be used to provide manual external cooling when cutters are
used to enlarge existing holes, or when using spiral bits not designed for automatic cooling.
If necessary the ARE adaptor can also be used to clean various parts of the drill, by means of the
lubrocoolant pressure jet, e.g. parts such as the tool clamping seat in the spindle shaft, seats for
the jig fixing screws, etc.
ARE adaptor
FIG. 5 – ARE ADAPTOR
10
5. SPINDLE ADVANCE LEVER
The spindle is advanced by moving the lever (36)
(See Fig. 6 a). The lever is fitted with a release pawl
(39) which, when pressed, renders it independent
of the hub and hence the spindle; the operator
can therefore easily vary the angular position of
the lever without movement of the spindle (Fig.6).
FIG. 6
36
6a - Moving the lever (36) towards the operator pro duces a corresponding advance of the spindle.
6b - With the release pawl (39) pressed, the le ver is released 6c - With the hub released, moving the lever towards
rom its hub and can repeat the previous travel without the operator produces a corresponding advance of
the spindle moving.
this spindle.
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).
11
FIG. 7
6. PREPARING THE DRILL
STOP THE ENGINE when servicing the drill: before removing the broach
cutters, spiral bits, positioning templates etc.
6.1) Assembling broach cutters (Ref. to Figs. 8-11).
6.1.1) Insert the guide bit in the cutter from the side of the spigot.
6.1.2) Using the lever (36), position the spindle shaft (07) so that both grub screws (18) become
accessible and sufficient space is provided to insert the cutter; if necessary rotate the spindle
shaft manually and sufficiently by inserting the 4 mm 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: 25 mm
Guide bit PP...
07
Guide bit PPL ...
FIG. 8 – ASSEMBLING BROACH CUTTERS
Long type broach cutter
Maximum drilling thickness: 50 mm
6.2) Assembling spiral bits (Ref. to Figs. 9 - 11)
6.2.1) Using the advance lever, position the spindle shaft so that both grub screws become
accessible and sufficient space is provided to insert the spiral bit; if necessary rotate the
spindle shaft manually and sufficiently by inserting the 4 mm male hexagon key in the
appropriate intermediate gear housing in the crankcase of the drill corresponding to
the feed handle (see Fig. 11).
12
6.2.2)
6.2.3)
6.2.4)
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 first be fitted 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.
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).
Clamp the bit by fully tightening the two grub screws (18) using the 4 mm male allen key.
APE ...
18
Bits PE ... (e.g. PE70)
DPE *
07
Bits PE ... (e.g. PE 220)
DPE
* use only for APE, not required for APED
FIG. 9 – ASSEMBLING SPIRAL BITS
FIG. 10 –
71
33
FIG. 11 – MANUAL SPINDLE
ROTATION
13
ASSEMBLING THE
BIT-SPACER UNIT
7. DRILL TYPE LD-41P
Part code LD-41P consist of the LD-41PN basic drill (see page 1) complete with the DBG-F2
moving arm device for clamping to the rail web and track fittings (Ref. to Fig. 12).
The DBG-F2 clamping device consists of:
– Clamping unit
– Type TDB 1 end piece
– Type TDB 3 end piece
– Type TDB 6 standard end piece
– Socket head cap screws M8x25 (2 pcs)
– Spring washers (4 pcs)
– Reference pin
reference
pin
TDB 3
TDB 6
M 8x25 screws
and spring washers
TDB 1
FIG. 12 – DRILL TYPE LD-41P
14
7.1) Assembling the end pieces
TDB 1, TDB 6 and TDB 3 end pieces of the DBG-F2 device, with moving arm, have been designed
for adaptation to the different operating conditions on rails and track fittings;
their assembly is shown in Fig. 13.
• When assembling the TDB 3 end piece ensure that the positioning pawl is pointing downward
in relation to the bolt.
• When disassembling the TDB 6 end piece ensure that, after removing the pivot, the complete assembly is slid away downward without acting on the holding plate.
• Over-advancing the spindle after drilling must be avoided when using the TDB 1 and TDB 3 end
pieces.
holding
plate
TDB 1 end piece for switch blades
and composite frogs
TDB 3 end piece
for enlarging existing holes
on rails inherent in the application
of electrical connections and for
additional special applications.
TDB 6 end piece for rails and stock rails
Seats to be used for
special applications.
positioning pawl
pointing downwards
FIG. 13 – ASSEMBLY OF END PIECES
7.2) Assembly of the DBG-F2 clamping device on the drill
The DBG-F2 clamping device is fitted to the front plate of the drill, centred by means of the reference pin supplied and secured with the two socket head cap screws M8x25 (35) also supplied.
The assembly is illustrated in Fig. 14.
15
DBG-F2
FIG. 14 – ASSEMBLY OF
DBG-F2 CLAMPING DEVICE
35
Drilling machine
front plate
7.3) Assembly of positioning templates (Ref. to Fig. 15)
NOTE: Only Cembre positioning templates and jigs are to be used with the rail drill.
7.3.1) The type MPAF.. and MPAU positioning templates are secured to the front plate (22) of
the drill by means of the two screws M 6x16 supplied.
reference pin
MPAU
22
screws M6x16
MPAF...
FIG. 15 – ASSEMBLY OF TEMPLATES
16
7.4) Clamping to the rail web (Ref. to Fig. 16)
The drill has a rapid rail engagement/release mechanism and specially shaped positioning templates for each rail type which facilitate precise and certain location of the part to be drilled.
To fully exploit the special features of the engagement device, we recommend calibrating it to
the rail type to be drilled as follows:
– Withdraw the spindle shaft (07) completely by means of the lever (36).
– Insert the threaded bush (39) of screw (11) into its seat (A) in the mobile arm (17) (see detail in
Fig. 16); use the hand-wheel (12) to completely open the mobile arm.
– Place the drill on the track at the point to be drilled and clamp it by tightening the handwheel
fully down (12): the positioning template will automatically position the cutter or drill bit in
line with the designated axis; if precise positioning is necessary to the longitudinal track axis,
use the reference pin (18).
– For rapid drill release, simply back-off the hand-wheel (12) by approximately two complete
turns, and while supporting the drill by its grip (09), pull the hand-wheel towards you. The
threaded bush (39) will disengage the seat (A) in the mobile arm (17) which will open automatically, freeing the drill.
In this way, the operator can rapidly remove the machine from the track in case of danger, or
move on to drill another hole.
Thus, the next track engagement operation will be considerably simplified:
after positioning the drill at the point to be drilled, simply push the hand-wheel forward so that
the threaded bush engages the seat (A) of the mobile arm. Now, a few turns on the hand-wheel
will be sufficient to engage the drill correctly on the track.
11
09
36
²
17
12
39
A
18
39
07
FIG. 16 –
POSITIONING THE DRILL
17
²
11
03
17
8. DRILLING
Check engine oil level before operation (see § 13.2.4).
Switch on the cooling system before starting the drill (see § 4).
8.1) Drill fitted with “short” type broach cutter (for drilling thicknesses of up to 25 mm).
The drilling sequence may be started with the drill fitted with the broach cutter (§ 6.1), clamping
end piece (§ 7.1), positioning template (§ 7.3), the drill being clamped to the rail (§ 7.4), as follows:
8.1.1) Connect the female quick-coupling of the SR5000 coolant unit to the male coupling (35)
on the drill.
8.1.2) Open the tap (02) fitted on the coolant unit hose.
8.1.3) Using the lever (36) bring the guide bit
Fig. 17a
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
36
will enable the travel of the lever (36) to
be used in the most advantageous way.
FIG. 17 – DRILLING
Fig. 17b
Fig. 17c
39
18
8.1.4)
8.1.5)
8.1.6)
8.1.7)
8.1.8)
Start the engine, following instructions § 11.
Proceed to drill by initially applying light pressure on the lever (36), increasing the
pressure progressively, avoiding jolts, and finally relieving the pressure in the exit phase.
When drilling close to raised markings on the rail the initial pressure must be extremely
light until the markings disappear, otherwise the cutter may be damaged.
The guide bit will enable the lubrocoolant to be discharged throughout the drilling process.
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.
After drilling it is advisable to remove with the brush all swarf from the broach cutter or
spiral bit and spindle area.
8.2) Drill fitted with “long” type broach cutter (for drilling thicknesses of up to 50 mm).
Follow the sequence described in § 8.1, taking care to position the drill on the rail by keeping the
spindle fully withdrawn.
11
36
02
35
39
FIG. 18 – DRILLING
19
Approach
Start drilling
with discharge of
lubrocoolant
Drilling
Finish drilling
with removal of swarf and
switching off of
lubrocoolant
The slug is ejected upon completion of the drilling operation
FIG. 19 – COOLANT DRILLING WITH BROACH CUTTER
8.3) Drill fitted with special spiral bit
Follow the sequence described in § 8.1, taking care to position the drill on the rail by keeping
the spindle fully withdrawn. Bear in mind that the coolant circuit, instead of being automatically
opened and closed by the guide bit, is kept open at all times by the DPE spacer fitted on the
spigot of the spiral bit; it must therefore be activated, by opening the tap (02), before starting to
drill, then switched off after drilling by closing the tap.
FIG. 20a
PE 70 - PE 165 spiral bits
(drilling diameters from 7 to 16,5 mm)
DPE spacer
APE adapter
Spiral bit
FIG. 20b
PE 170 - PE 275 spiral bits
(drilling diameters from 17 to 27,5 mm)
FIG. 20 – COOLING DRILLING WITH SPIRAL BIT
20
9. SPA... POSITIONING PLATE
9.1) Instruction for drilling close to rail heads
02
03
FIG. 21
9.1.1) Fit the MPAF... positioning template corresponding to the rail to be drilled (see § 7.3).
9.1.2) Insert the SPA... positioning plate (03) relating to the rail to be drilled in the appropriate
housing (see Fig. 21).
9.1.3) Insert the locking pin (02) in one of the two holes of the positioning plate.
9.1.4) With the spindle fully withdrawn, position the drill close to the rail head without clamping it.
9.1.5) Slide the drill so that:
– the curved end of the SPA... positioning plate is flush against the rail head.
– the MPAF... positioning template is flush against the locking bolt (02).
9.1.6) Clamp the drill in this position by tightening the handwheel fully, and commence drilling
(see § 8.1).
9.1.7) To drill the second hole in the rail, repeat operations 9.1.5 - 6 with the locking pin (02)
inserted in the second hole of the SPA... positioning plate.
For clarity the drill is not shown
in the figures
02
FIG. 22 – POSITIONING
21
9.2) Drilling in line with rail heads (Ref. to Figs. 23-24)
9.2.1) Fit the MPAF... positioning template corresponding to the rail to be drilled (see § 7.3 or 9.1).
9.2.2) Fit the MRF clamp on the head of the rail, keeping it in contact with the rail head at the
reference point of the drilling centres. Lock it in position with the lever. The lever is provided
with a return pushbutton for moving in any direction after locking (See Fig. 23).
9.2.3) Insert the SPA... positioning plate so that the curved part is facing upwards.
9.2.4) Insert the locking pin (02) in one of the two holes of the connection plate.
9.2.5) With the spindle fully withdrawn, position the drill close to the MRF clamp, without locking
the spindle.
9.2.6) Slide the drill so that:
– the curved end of the SPA... plate is flush against the MRF clamp on the side identify ing the reference point for distances.
– the MPAF... positioning template is flush against the locking bolt (02) (see Fig. 24).
9.2.7) Clamp the drill in this position by tightening the handwheel fully, and commence drilling
(see § 8.1).
9.2.8) To drill the second hole in the rail, repeat operations 9.2.6 - 7 with the locking pin (02)
inserted in the second hole of the SPA... plate.
22
02
For clarity the drill is not shown in the
figures
Reference point for distances
02
Reference point for distances
FIG. 24 – POSITIONING
23
10. CHECK FUEL
WARNING
- Petrol is extremely flammable and explosive.
- DO NOT SMOKE.
- Refuel in a well ventilated area away from flame or sparks.
- Stop engine and allow it to cool before refueling.
When handling petrol:
- Risk of intoxication, avoid inhalation of petrol vapours.
- Risk of irritation, avoid prolonged and repeated contact with skin.
- Exhaust gas contains carbon monoxide, an odourless and deadly
poison.
- Do not run engine in an enclosed area.
- To avoid a serious burn, do not touch a hot engine or exhaust.
- The engine becomes hot during operation.
- To avoid an electric shock, do not touch spark plug, plug cap or spark
plug lead during engine running.
The LD-41P drilling machine features a 4-stroke petrol engine run on unleaded regular grade
petrol 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.
– Refill fuel to the upper level.
– Do not overfill with fuel.
– When filling the fuel tank, always use the fuel filter.
– Wipe off any spilled fuel before starting the engine.
FUEL FILLER
CAP
TAPPO
SERBATOIO
MAXIMUM
LIVELLO
SUPERIORE
FUEL LEVEL
FUEL
FILLER CAP
24
11. STARTING THE ENGINE
Before starting the engine, ensure that:
- the spindle shaft is fully retracted.
- the accelerator control lever is positioned at the low speed
position "0".
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.
NOTE: the engine will perform at its optimum after
a "running-in" period of
approximately 200 drilling
operations.
25
d)
a)
b)
c)
e)
12. STORING THE DRILL
When work has been completed, put away the drill by proceeding as follows:
12.1) Depressurise the tank of the SR5000 cooling unit (see § 4), close the tap (02) on the tube
from the tank, and disconnect the quick-coupling (03).
12.2) Carefully clean the drill, particularly in the spindle area, removing machining waste (swarf,
etc.) and any deposits of lubricating coolant.
12.3) Fully withdraw the spindle.
12.4) Place the drill and the SR5000 cooling unit in a sealed place free from dust, moisture and
the risk of accidental impact.
For better protection Cembre recommends the use of the VAL P24 plastic case or VAL P24-CS
(variant with folding handle and wheels, see Fig. 24a) designed for this purpose (see § 3.2). The
DBG-F2 moving arm device allows the drill to be housed and locked in the case. Suitable housings are also provided in the plastic case for containing the most commonly used accessories.
ACCESSORIES
RAIL DRILL
ACCESSORIES
PLASTIC CASE
FIG. 24a VAL P24-CS STORAGE PLASTIC CASE
26
13. MAINTENANCE
Before you service or remove parts, stop the engine and allow it to cool.
Always remove the spark plug cap from spark plug when servicing the engine
to prevent accidental starting.
After the first 10 operating hours, proceed with sump oil change, as follows:
(Ref. to Figs. 25 and 25a)
– Remove the cap with the magnetic insert (28).
– Remove the oil filler cap (07).
– Make sure that all the oil comes out by tilting slightly the
drilling machine in order to make the operation easier.
07
– Clean the cap (28) (see § 13.1.2).
–­ Reassemble the cap.
– Fill the oil sump to the level indicator (see § 13.1.1) using the
oil supplied with the drilling machine; it will be necessary to
use about 100 ml oil.
– Replace the oil filler cap (07).
FIG. 25
Ensure that disposal of used oil is
in accordance with current legislation.
13.1) ORDINARY MAINTENANCE OF THE DRILL
19
Every 20 hours of operation
13.1.1) Topping up oil (Ref. to Figs. 25 and 25a)
With the drill switched off and placed on a flat surface, check
the oil level in the crankcase by looking through the transparent
inspection cover (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.
27
FIG. 25a
28
13.1.2) Removal of metal residues from the
crankcase
When the drill is positioned as shown in Fig. 26 unscrew
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. 26 – REMOVAL OF
METAL RESIDUES
28
Every 50 hours of operating
13.1.3) Checking of screws.
– Check and re-tighten all screws where necessary.
13.1.4) Lubrication (Ref. to Figs. 33 and 34)
– Lubricate the spindle support housing by means of the appropriate lubricator (25), the screw
of the DBG-F2 clamping device.
13.1.5) Cleaning of coolant filter (Ref. to Fig. 27)
The coolant system of the drilling machine is provided with anti-impurity filter; should a decrease
of the flow of the lubrocoolant be noticed, it may be necessary to clean it in the following way:
– Using a 14 mm key, unscrew the coupling (02).
– Extract the filter and clean it carefully.
– Reassemble the filter into the coupling (02) as shown in the Fig. 27, fully tighten the coupling.
anti-impurity filter
02
FIG. 27 – CLEANING OF COOLANT FILTER
28
13.2) 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
13.2.1) Fuel filter cleaning (Ref. to Fig. 28)
– Check that the engine oil filler cap is tightened securely.
– Remove the fuel filler cap, and drain the fuel into an approved gasoline container by tipping
the engine toward the fuel filler neck.
– Pull the fuel filter out through the fuel filler neck by
hooking the black fuel tube with a piece of wire, such
as a partly straightened paper clip.
– Inspect the fuel filter. If the fuel filter is dirty, wash it
gently with nonflammable or high flash point solvent.
If the fuel filter is excessively dirty, replace it.
– Remove water and dirt from inside the fuel tank by
rinsing it out with non-flammable or high flash point
solvent.
fuel filter
– Insert the fuel filter into the fuel tank and tighten the
FIG. 28 – FUEL FILTER CLEANING
fuel filler cap securely.
Improper use of solvents can result in fire or
explosion.
Every 3 months or 25 hours of operation
13.2.2) Air filter cleaning (Ref. to Fig. 29)
– Press the latch tab (A) on the top of the air cleaner
cover and remove the cover.
– Clean the filter element in warm soapy water, rinse and
allow to dry thoroughly, or clean in non flammable
solvent and allow to dry.
– Dip the filter 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 filter element and air cleaner cover.
Always replace damaged filter elements.
Operating in dusty condition may require more frequent
maintenance than above.
Do not operate the engine with air filter removed.
29
A
filter element
FIG. 29 – AIR FILTER CLEANING
Every year or 100 hours of operation
13.2.3) Spark plug cleaning (Ref. to Fig. 30)
– Using a 4 mm allen key remove the fixing 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
spark plug
1/8-1/4 turn with the key to copress the washer.
A loose spark plug can overheat and damage
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 fixing screw.
– In case of plug replacement, use type NGK CM5H,
CMR5H or equivalents.
FIG. 30 – SPARK PLUG CLEANING
13.2.4) Check engine oil (each use) (Ref. to Fig. 31)
Before checking or refilling engine oil, be sure the machine is located on a stable, level surface
and stopped.
– Remove the oil filler cap/dipstick and wipe it clean.
– Insert the oil filler cap/dipstick without screwing it into the oil filler 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, fill to the bottom edge of
the oil fill hole with the recommended oil (see § 1).
– Change oil if it is contaminated.
– Wipe off any spilled oil before starting the engine.
OIL FILLER CAP/DIPSTICK
– Reinstall the oil filler cap/dipstick and tighten securely.
LIMITE
UPPER
LIMIT
SUPERIORE
LIMITE
UPPER LIMIT
SUPERIORE
LOWER LIMIT
FIG. 31 – CHECK ENGINE OIL
OIL FILL HOLE
(bottom edge)
30
13.2.5) Engine oil change (Ref. to Figs. 31 and 32)
Initial oil change: first 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 filler cap is tightened securely.
Place a suitable container below the engine to catch the used oil.
Remove the oil filler cap/dipstick and drain the oil into the container by tipping the machine
toward the oil filler neck.
Some oil will remain in the engine after draining, when refilling with fresh oil, start with less
than 80 ml (2.7 US oz).
– With the engine in a level position, fill to the bottom edge of the oil fill hole (Ref. to Fig. 31 and
32) with the recommended oil (see § 1).
– MAX OIL CAPACITY: 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.
oil filler
cap/dipstick
Ensure that disposal of used oil is in
accordance with current legislation.
13.2.6) Checking of screws
– Check and re-tighten all screws where necessary.
FIG. 32 – ENGINE OIL CHANGE
13.3) SPECIAL MAINTENANCE OF THE DRILL
The special maintenance operations require the intervention of qualified personnel only, please
contact Cembre (See § 15).
13.3.1) 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 cm3 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. 33 – LD-41PN DRILL ASSEMBLY
32
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
Magnetic cap
M 4x8 screw
Cooling connection guard
Lubricator
Front plate
Drilling spindle
Complete air valve
M 8 x 10 grub screw
Fuel filter
Level gauge
Fuel tank
Handle Screw
Fuel tank cap
ON/OFF Switch
Description
Code N° Item
6001209
6900060
6001731
6001198
6002607
6002602
6001397
6340160
6001195
6900346
6001211
33
28
27
26
25
24
23
22
21
20
19
18
17
16
15
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
14
13
12
11
10
09
08
07
06
05
04
03
02
01
Code N° Item
Starting handgrip
Engine
Air filter element
Spark plug
Handle
Complete handgrip
Accelerator lever
Cap
Carriage handle
Spindle advancing lever
O-ring
Lever release pawl
Complete cooling connection
Body
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Description
Qty
34
01
02
04
05
06
37
16
17
03
07
09
20
35
22
23
24
19
28
32
34
11
FIG. 34 –
DBG-F2 RAIL WEB CLAMPING DEVICE
21
13
18
14 15
10
08
29
27
26
25
31
33
36
37
36
35
34
33
32
31
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
11
10
09
08
07
06
05
04
03
02
01
Code N° Item
6001155
6002871
6001762
6001768
6001769
6180201
6001776
6760378
6340612
6900314
6900348
6650144
6760222
6140082
6001138
6140082
6001775
6140080
6001137
6040421
6001156
6001907
6001906
6001757
6001772
6340160
6380310
6001150
6001151
6001659
6001152
6520422
6140085
6001145
6001281
Description
Spacer
Stop pin
Complete bush
Spring support spacer
Spring
M 5 self-locking nut
Pin
ø 8x50 cylindrical pin
M 5 ball dowel
M 6x18 screw
M 8x25 screw
ø 8 elastic washer
ø 4x10 cylindrical pin
ø 1,8x35 split pin
TDB1 end piece
ø 1,8x35 split pin
TDB6 end piece
Split pin
TDB3 end piece
ø 10 circlip
Pin
Left support shoulder
Right support shoulder
Blocking side plate
Pin
M 8x10 grub screw
Handgrip
Hand-wheel
Blocking screw
Spacer
Bush
Cup spring
ø 2,5x15 split pin
Blocking support
Reference rod
Qty
1
1
1
1
2
2
2
2
2
4
2
4
1
2
1
1
1
2
1
1
1
1
1
2
2
1
2
1
1
1
1
1
1
1
1
14. WARNINGS
14.1) Regularly check for correct tightening (torque) of the fixing screws of the drilling tools and
positioning templates.
14.2) Avoid pressure jolts on the advancing lever during drilling.
14.3) Always make sure that the drilling swarf is properly removed before starting to drill a new
hole.
14.4) Incomplete clamping of the drill on the rail to be drilled may lead to the breakage or accelerated wear of the drilling tool and damage to the spindle shaft bearings.
14.5) If it is necessary to operate the drill without the cutter inserted, remove the locking grub
screws from the spindle shaft.
14.6) Avoid leaving the SR5000 tank under pressure and exposed to sunlight for long periods of
time.
14.7) Should the DBG-F2 clamping device be removed, make sure that by reassembling it, the
two locking screws are firmly fastened.
15. RETURN TO Cembre FOR OVERHAUL
In the case of a breakdown contact our Area Agent who will advise you on the problem and give
you the necessary instructions on how to dispatch the tool to our nearest service Centre; if possible, attach a copy of the Test Certificate supplied by Cembre together with the tool or fill in
and attach the form available in the “ASSISTANCE” section of the Cembre website.
APPENDIX “A”
Factors which influence the number of holes that can be made according to the tool used:
–
–
–
–
Hardness of the material to be drilled.
Thickness to be drilled.
Stability of the drill 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 efficiency 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 efficiency.
– Observance of these basic rules:
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 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 efficient 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 flow rate.
35
This manual is the property of Cembre.
Any reproduction (in full or in part) is forbidden without the prior written permission of Cembre.
Cembre reserve the right to modify the specifications in this manual without prior notice.
Cembre S.p.A.
Via Serenissima, 9
25135 Brescia (Italia)
Telefono: 030 36921
Telefax: 030 3365766
E-mail: sales@cembre.com
www.cembre.it
Cembre Ltd.
Dunton Park
Kingsbury Road, Curdworth - Sutton Coldfield
West Midlands B76 9EB (Great Britain)
Tel.: 01675 470440 - Fax: 01675 470220
E-mail: sales@cembre.co.uk
www.cembre.co.uk
Cembre España S.L.
Calle Verano, 6 y 8 - P.I. Las Monjas
28850 Torrejón de Ardoz - Madrid (España)
Teléfono: 91 4852580
Telefax: 91 4852581
E-mail: comercial@cembre.es
www.cembre.es
Cembre GmbH
Heidemannstraße 166
80939 München (Deutschland)
Telefon: 089 3580676
Telefax: 089 35806777
E-mail: sales@cembre.de
www.cembre.de
Cembre S.a.r.l.
22 Avenue Ferdinand de Lesseps
91420 Morangis (France)
Tél.: 01 60 49 11 90 - Fax: 01 60 49 29 10
CS 92014 – 91423 Morangis Cédex
E-mail: info@cembre.fr
www.cembre.fr
Cembre Inc.
Raritan Center Business Park
181 Fieldcrest Avenue
Edison, New Jersey 08837 (USA)
Tel.: 732 225-7415 - Fax: 732 225-7414
E-mail: Sales.US@cembreinc.com
www.cembreinc.com
36
cod. 6261199
www.cembre.com
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