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Cembre LD-4P Operation And Maintenance Manual

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OPERATION AND MAINTENANCE MANUAL
ENGLISH
ENGLISH
(Translation of the original instructions)
1
RAIL DRILL
LD-4P

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Summary of Contents for Cembre LD-4P

  • Page 1 RAIL DRILL LD-4P OPERATION AND MAINTENANCE MANUAL ENGLISH ENGLISH (Translation of the original instructions)
  • Page 2 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 cut- ters, spiral bits, positioning templates etc.
  • Page 3 GENERAL SAFETY RULES General safety rules: For multiple hazards, read and understand the safety instructions before installing, operating, repairing, maintaining, changing accessories on, or working near the drill. Failure to do so can result in serious bodily injury. Only qualified and trained operators should install, adjust or use the drill. Do not modify this drill.
  • Page 4 Entanglement hazards: Choking, scalping and/or lacerations can occur if loose clothing, personal jewellery, neckware, hair or gloves are not kept away from the tool and accessories. Operating hazards: Use of the tool can expose the operator’s hands to hazards, including cuts, abrasions and heat.
  • Page 5 Repetitive motions hazards: When using a drill to perform work-related activities, the operator can experience discomfort in the hands, arms, shoulders, neck or other parts of the body. While using a drill, the operator should adopt a comfortable posture while maintaining a secure footing and avoiding awkward or off-balanced postures.
  • Page 6 Dust and fume hazards: Dust and fumes generated when using drills can cause ill health (for example, cancer, birth defects, asthma and/or dermatitis); risk assessment and implementation of appropriate controls for these hazards are essential. Risk assessment should include the dust created by the use of the tool and the potential for disturbing existing dust.
  • Page 7 If the drill has a silencer, always ensure that it is in place and in good working order when the drill is operating. Vibration hazards: Exposure to vibration can cause disabling damage to the nerves and blood supply of the hands and arms. Wear warm clothing when working in cold conditions and keep your hands warm and dry.
  • Page 8 1. GENERAL CHARACTERISTICS 7 - 40 Drilling capacity Ø mm 50 * Max. thicknesses * Speed without load 17,1 Weight 20,3 Weight with DBG-F2: SHELL SPIRAX S4 TXM o Gear oil : MOBIL SUPERMULTIGRADE 10-30-SAE or equivalents HONDA GX50NT-STSC-OH Conbustion engine: type 4-stroke, overhead camshaft, single cylinder 47,9...
  • Page 9 – Usage of the device for its intended purpose also incorporates compliance with the operating manual, including the manufacturer‘s maintenance recommendations and specifications. Part code LD-4P consist of the LD-4PN basic drill complete with the DBG-F2 moving arm device for clamping to the rail web and track fittings.
  • Page 10 2. ACCESSORIES SUPPLIED WITH THE DRILL 2.1) Guide bits for controlling the coolant system: for broach cutters suitable for drilling thickness up to 25 mm PP 1 (1 pc) diameter 7 mm. PP 2 (1 pc) diameter 8 mm. for broach cutters suitable for drilling thickness up to 50 mm PPL 1 (1 pc) diameter 7 mm.
  • Page 11 3. ACCESSORIES TO BE ORDERED SEPARATELY 3.1) DBG-LF2 device with moving arm complete with TDB 7 end piece for clamping the drill to girder rails and for additional special applications. TDB 7 3.2) “VAL-P24” plastic carrying case for storing the drill complete with the DBG-F2 device and accessories.
  • Page 12 – MPAF-UIC54 on DRILLING AXIS of 54E1 rail – MPAF-UIC60 on DRILLING AXIS of 60E1 rail • Note: Contact CEMBRE for selection of specific application accessories (e.g.: positioning templates for other rail profiles). 3.6) MPAU universal positioning template suitable both for repairing existing holes on various fittings, and for drilling disused rails.
  • Page 13 CY320 CY320L CY330 CY330L CY360 Max. thicknesses Max. thicknesses 25 mm 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.
  • Page 14 3.11) Spiral bits APED... FIG. 1 APE... L max L max FIG. 2 SPECIAL SPIRAL BITS FOR RAILS IN STEEL QUALITY 700 - 900 - 1100 (UIC 860.0) Spiral Bit Spiral Bit Adaptor Adaptor Ø Ø ref. ref. ref. ref. PE 70 PE 140 APED 70...
  • Page 15 (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.
  • Page 16  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. –...
  • Page 17 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).
  • Page 18 Be careful of the broach cutter’s sharp edges. Always wear work gloves to avoid injury. The drill spindle is factory-set to operate with CEMBRE CY range broach cutters fitted with Quick push/turn coupling; use of broach cutters and twist drill bits fitted with Weldon shank only requires disassembly of the transverse pin in the spindle (Ref.
  • Page 19 6.2) Assembling broach cutters with Weldon shank Using the spindle lever, advance the spindle to make the transverse threaded pin accessible; tooltip if it is not in a easily-accessible position, rotate the spindle shaft manually and sufficiently by inserting the 4mm T-handle Allen key in the appropiate intermediate gear housing (33) in the crank case of the drill (Ref.
  • Page 20 6.3) Assembling special spiral bits Using the spindle lever, position the spindle shaft so that both grub screws (18) become accessible. Insert the spiral bit in the corresponding APED adapter (1) and lock it with the grub screw (19) using the 4 mm T-handle Allen key (2) (Ref.
  • Page 21 6.4) Assembling terminations on DBG-F2 clamping device TDB 1, TDB 6 and TDB 3 terminations 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/disassembly is shown in the Figures. Normally they are mounted in the central holes of the clamping device.
  • Page 22 6.6) Assembling positioning templates Only CEMBRE positioning templates and jigs are to be used with the rail drill. Choose the correct positioning template for the rail profile to be drilled. Place the positioning template on to the front plate of the drill, aligning the two reference pins with the holes in the template.
  • Page 23 6.7) Fitting “double sided” templates Compared to the templates for positioning rail drills, the KPAF "double sided templates" are equipped with a double profile that enables positioning of the drill on two different types of rail by simply inverting them. They are fixed on the sides of the front plate.
  • Page 24 6.8) Clamping to the rail web (Ref. to Fig. 8) 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: –...
  • Page 25 7. FUEL PREPARATION 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.
  • Page 26 8. STARTING THE ENGINE Before starting the engine, ensure that: - the engine oil level is correct. - the spindle shaft is fully retracted. - the accelerator control lever is positioned at the low speed position “0”. 8.1) Set the engine “ON/OFF” switch to the “ON” position (Fig.
  • Page 27 9. DRILLING Check engine oil level before operation (see § 13.2.1). Switch on the cooling system before starting the drill (see § 4). 9.1) 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, clamping end piece, positioning template, the drill being clamped to the rail, as follows: 9.1.1) Connect the female quick-coupling of the SR5000 coolant unit to the male coupling (35) on the drill.
  • Page 28 9.1.4) Start the engine, following instructions § 8. 9.1.5) 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.
  • Page 29 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. 11 – COOLANT DRILLING WITH BROACH CUTTER 9.3) Drill fitted with special spiral bit Follow the sequence described in §...
  • Page 30 10. SPA... POSITIONING PLATE 10.1) Instruction for drilling close to rail heads FIG. 13 10.1.1) Fit the MPAF... positioning template corresponding to the rail to be drilled. 10.1.2) Insert the SPA... positioning plate (03) relating to the rail to be drilled in the appropriate housing (see Fig.
  • Page 31 10.2) Drilling in line with rail heads 10.2.1) Fit the MPAF... positioning template corresponding to the rail to be drilled . 10.2.2) 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.
  • Page 32 For clarity the drill is not shown in the figures Reference point for distances Reference point for distances FIG. 16 – POSITIONING...
  • Page 33 11.4) 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. The DBG-F2 moving arm device allows the drill to be housed and locked in the case.
  • Page 34 12. WARNINGS 12.1) Regularly check for correct tightening (torque) of the fixing screws of the drilling tools and positioning templates. 12.2) Avoid pressure jolts on the advancing lever during drilling. 12.3) Always make sure that the drilling swarf is properly removed before starting to drill a new hole.
  • Page 35 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.
  • Page 36 13.1.2) Removal of metal residues from the crankcase (Rif. a Fig. 18) When the drill is positioned 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.
  • Page 37 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. 13.2.1) Check engine oil (each use) Before checking or refilling engine oil, be sure the machine is located on a stable, level surface and stopped.
  • Page 38 Every 3 months or 25 hours of operation 13.2.3) Air filter cleaning – Loosen the screw (1) and remove the air cleaner cover (2). – Inspect the air filter element (3). – Clean or replace dirty air filter element. Always replace damaged air filter element.
  • Page 39 Every year or 100 hours of operation 13.2.5) Spark plug cleaning – 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.
  • Page 40 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. 24 – DRILL ASSEMBLY...
  • Page 41 6001209 Magnetic cap Starting handgrip 6900060 M 4x8 screw Engine 6001731 Cooling connection guard Air filter element 6001198 Lubricator 6003698 Spark plug 6005033 Front plate 6380330 Handle 6004688 Drilling spindle 6003612 Complete handgrip 6001397 Complete air valve 6001166 Accelerator lever 6340160 Grub screw 6003034...
  • Page 43 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.
  • Page 44 DECLARATION DE CONFORMITE - KONFORMITÄTSERKLÄRUNG - DECLARACIÓN DE CONFORMIDAD - DICHIARAZIONE DI CONFORMITÁ We Nous Wir Nos Noi: CEMBRE S.p.A. Via Serenissima, 9 – 25135 Brescia (Italy) Declare under our sole responsibility that the product - Déclarons sous notre seule responsabilité que le produit - Erklären in alleiniger Verantwortung dass das Produkt - Declaramos bajo nuestr responsabilidad que el producto...