4-CYCLE. This manual is the property of Cembre. Cembre reserve the right to modify the specifications in this manual without prior notice.

Transcription

1 08 M 076 U 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. 4-CYCLE HONDA ENGINE Certified Quality Management System Certified Environmental Management System RAIL DRILL Certified Occupational Health & Safety Management System TYPE LD-4PY ENGLISH PATENTED Cembre S.p.A. Via Serenissima, Brescia (Italia) Telefono: Telefax: info@cembre.com Cembre España S.L. Calle Verano, 6 y 8 - P.I. Las Monjas Torrejón de Ardoz - Madrid (España) Teléfono: Telefax: info@cembre.es Cembre Ltd. Dunton Park Kingsbury Road, Curdworth - Sutton Coldfield West Midlands B76 9EB (Great Britain) Tel.: Fax: sales@cembre.co.uk Cembre AS Fossnes Senter N-360 Stokke (Norway) Phone: (47) Telefax: (47) cembre@cembre.no Cembre S.a.r.l. 22 Avenue Ferdinand de Lesseps 9420 Morangis (France) Tél.: Fax: B.P Morangis Cédex info@cembre.fr Cembre GmbH Heidemannstraße München (Deutschland) Telefon: 089/ Telefax: 089/ info@cembre.de cod Cembre Inc. Raritan Center Business Park 8 Fieldcrest Avenue Edison, New Jersey (USA) Tel.: (732) Fax: (732) Sales.US@cembreinc.com OPERATION AND MAINTENANCE MANUAL

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. During operation keep your hands outside the danger area. Always wear protective glasses and work gloves. Avoid wearing clothes which may present a risk to personal safety. Always check combustion engine oil level before operation! 5. WARNINGS 5.) Regularly check for correct tightening (torque) of the fixing screws of the drilling tools and positioning templates. 5.2) Avoid pressure jolts on the advancing lever during drilling. 5.3) Always make sure that the drilling swarf is properly removed before starting to drill a new hole. 5.4) 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. 5.5) If it is necessary to operate the drill without the cutter inserted, remove the locking grub screws from the spindle shaft. 5.6) Avoid leaving the SR5000 tank under pressure and exposed to sunlight for long periods of time. 5.7) Should the DBG-Y clamping device be removed, make sure that by reassembling it, the two locking screws are firmly fastened. 6. RETURN TO Cembre FOR OVERHAUL LD-4PNY basic drill 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 drill to our nearest service Centre; if possible, attach a copy of the Test Certificate supplied by Cembre together with the drill or, if no other references are available, indicate the approximate purchase date and the drill serial number. APPENDIX A Factors which influence the number of holes that can be made according to the tool used: LD-4PY (LD 4PN + DBG-Y) basic drill complete with railweb clamping device 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: ) 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 00 steel, it is advisable to increase the lubrocoolant flow rate. 34

3 Threaded bush ø4 Circlip ø0 Circlip Spacer Pin ø 8 x 50 pin M5 ball dowel M 6 x 8 screw Spring washer M 8 x 25 screw ø4 x 0 pin ø,8x35 Split pin TDB 6 termination Blocking side Clamping support left shoulder Clamping support right shoulder M 8 x 0 grub screw Clamping handle knob Blocking lever Compl. blocking screw Thickness Adjusting bush Cup spring ø2,5 x 6 Split pin Clamping support Drilling reference rod Code N Item Description Qty GENERAL CHARACTERISTICS. RAIL DRILL TYPE LD-4PNY The Cembre LD-4PNY drill powered by HONDA 4-cycle engine can be stored and continuously operated in full 360 inclination, thanks to the rotary-slinger pumping lubrication system. Drilling capacity:... 9/32" to /2" (with special twist drill bits: hole diameters of 9/32" to -/8" on rails up to 3 /2" thick) (with broach cutters: hole diameters of 3/4" to -/2" on rails up to 2 3/4" thick) Speed without load:... n 230 rpm Gear sump: Recommended oil:...shell SPIRAX S4 TXM or.mobil SUPER MULTIGRADE 0-30-SAE or equivalents. Weight: (LD-4PNY) lbs. Weight: (LD-4PY)...43 lbs FIG. 33 DBG-Y RAIL WEB CLAMPING DEVICE. Combustion engine (EPA/CARB compliant):. Type:... 4-cycle, overhead camshaft, single cylinder. Model:...Honda GX35NT STSC. Operating angle:...infinite. Displacement: cu-in (35,8 cm 3 ). Power (SAE J349):...,0 kw (,3 HP) / 7000 rpm. Fuel tank capacity: US gal (0,63 litre). Clutch:...centrifugal with automatic intervention. Start:...by rope pull. Ignition:...transistorized magneto. Spark plug:...ngk CM5H or CMR5H or equivalents. Fuel:... unleaded regular grade gasoline ( see 2). Recommended oil:... SAE 0W-30, API SJ or later Acoustic Noise (Directive 2006/42/EC, annexe, point letter u) The continuous equivalent weighted level (A) of noise pressure at the working place L pa is equal to...96,2 db (A) The maximum value of instantaneous weighted noise pressure C at the working place L pcpeak is...< 30 db (C) The level of noise force produced by the machine L WA is equal to...0,9 db (A) Risks due to vibration (Directive 2006/42/EC, annexe, point ) Tests carried out in compliance with the indications contained in UNI ENV and UNI EN part st 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/sec

4 2. ACCESSORIES SUPPLIED WITH THE DRILL 2.) Pilot bits for controlling the cooling system: for use with short broach cutters (7/8 " depth of cut) pc PPC 2 for use with long broach cutters (2 " depth of cut) pc PPL ) Spacer, type DPE, for use with spiral bits and APE adaptor for controlling 0 the cooling system ) 09 Adaptor, type ARE, for external cooling, to be used with the SR5000 cooling unit ) Grub screw, M8x0 4 pcs for clamping cutters or bits onto spindle shaft ) Socket head cap screws, M6x6 406 pcs for securing positioning shoes to front plate ) 05 Socket head cap screws, M6x25 4 pcs for securing special positioning shoes to front plate ) Range of tools: pc 5 mm allen key 03 pc 6 mm allen key pc 4 mm allen key with handle 02 pc spark plug key pc brush ) 3.4 fl oz (00 ml) oil bottle for gear sump. (Accessories from pos. 2. to pos. 2.8 are included in the Kit of accessories for LD-4PNY having the code ) 2.9) Type SR5000 cooling unit Code N Item Magnetic cap M 4x8 screw Cooling connection guard Lubricator Front plate Drilling spindle Complete air valve M 8 x 0 grub screw Fuel filter Level gauge Fuel tank Handle Screw Fuel tank cap ON/OFF Switch Description 2 2 Qty Code N 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 Item Description Qty 3 32

5 3. OPTIONAL ACCESSORIES (to be ordered separately) ) "DBG-Y" device with moving arm for clamping the drill to the rail web and track fittings, complete with the TDB 6 termination. Always supplied with drilling machine ref. LD-4PY ) "DBG-LY" device specific for clamping the drill to the girder rails (for example 28 GR or GGR 8). With the specific shoes allows the positioning on both sides of the rails, complete with thetdb 3 termination. 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 3..2) "DBG-GR" device for clamping the drill in correspondance of guard rail. Always supplied with drilling machine ref. LD-4PYGR FIG. 32 LD-4PNY DRILL ASSEMBLY 3 4

6 3.2) "TST50" two stage template (to be used with specific DBG-AY clamping device) This device enables the drilling of 50 lb and aluminium composite contact rails from one side. Restart of work stroke:,97 Typical application: Aluminium composite rail. 50 lbs contact rail. 3.3) VAL LD steel carrying case for storing the drill complete with the clamping device and VAL MPA tool case. 22 /2" (L) x 3 /2" (W) x 7 /2" (H) 4.2.5) Engine oil change (Ref. to Figs. 30 and 3) Initial oil change: first month or after 0 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 2.7 US oz (80 ml). With the engine in a level position, fill to the bottom edge of the oil fill hole (Ref. to Fig. 30 and 3) with the recommended oil (see ). MAX OIL CAPACITY: 3.4 US oz (00 ml). Always use the best grade and clean oil. Contaminated oil, poor quality oil and shortage of oil cause damage to engine or shorten the engine life. Ensure that disposal of used oil is in accordance with current legislation. oil filler cap/dipstick 3.4) VAL MPA suitable for storage of rail shoes, cutters and accessories 5 /2 (L) x 3 3/4 (W) x 2 /4 (H) 4.2.6) Checking of screws. Check and re-tighten all screws where necessary. FIG. 3 Engine oil change 4.3) Special servicing. 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.) "MPAU-0" universal SHORT rail shoe for rail or for special applications (positioning not automatic). 4.3.) Storing the drilling machine for long periods. Completely empty the fuel tank. Start the engine and let it run until it stops, so that all fuel is exhausted from the machine. Remove the spark plug. Pour 3-5 cm 3 of oil into the cylinder. Repeatedly pull gently on the starting rope so that dispersion of oil in the cylinder is achieved and reinstall the spark plug. Using a clean cloth soaked with motor oil, clean all metal parts of the machine. Store the drilling machine in its appropriate case or in a dry environment protecting it against accidental damage and dust. 5 30

7 Every year or 00 hours of operation 4.2.3) Spark plug cleaning (Ref. to Fig. 29) 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: mm ( in). Install the spark plug carefully, by hand, to avoid crossthreading. When installing a new spark plug, tighten /2 turn with the key to compress the washer. When reinstalling the original spark plug, tighten /8-/4 turn with the key to compress the washer. A loose spark plug can overheat and damage the engine. Overtightening the spark plug 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. 29 SPARK PLUG CLEANING 3.2.4) Check engine oil (each use) (Ref. to Fig. 30) 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 ). 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. MITE UPPER ERIORE LIMIT FIG. 30 Check engine oil LIMITE UPPER SUPERIORE LIMIT LOWER LIMIT OIL FILL HOLE (bottom edge) 29 6 Rail Shoes Drilling On Running Rails TYPE OF RAIL H (inch) 40 LB ASCE 3 /6" 60 LB ASCE 3 /6" 80 LB ASCE 2 3/6 85 LB ASCE 2 7/64 85 LB PRR 2 /6 85 LB PS 2 5/64 90 LB ARA-A 2 9/6 90 LB ASCE 2 45/28 00 LB ARA-A 2 3/4 00 LB ARA-B 2 65/28 00 LB ASCE 2 65/28 00 LB DY 2 5/8 00 LB NYNH&H 2 39/64 00 LB RE 2 45/64 00 LB RE-HF 2 45/64 00 LB PRR 2 9/32 00 LB PS 2 3/64 05 LB DY/0 LB RE 2 43/64 2/5/9 LB RE 2 7/8 22 CB 2 7/8 27 LB DY 3 /8 30 LB RE/HF-A 2 3/4 30 LB RE-HF 3 /6" 30 LB HF-B 3 3/8 30 LB PS 2 3/4 3 LB RE 3 /2 32 LB RE 3 3/32 33 LB RE 3 36 LB RE 3 3/32 36 LB LE VAL 3 /6 40 LB RE/40 PS 3 4 LB AB/ 4 LB RE 3 3/32 52 LB PS 3 3/4 55 LB PS rail 3 3/8 (*) to be used with PFA arbour extension and PPL5 Pilot Bit ) "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 specific rail. Note: Please contact Cembre for other types of rail. Rail Shoe MPAF 40 LB ASCE MPAF 60 LB ASCE MPAF 80 LB ASCE MPAF 85 LB ASCE MPAF 85 LB PRR MPAF 85 LB PS MPAF 90 LB ARA-A MPAF 90 LB ASCE MPAF 00 LB ARA-A MPAF 00 LB ARA-B MPAF 00 LB ASCE MPAF 00 LB DY MPAF 00 LB NH MPAF 00 LB RE MPAF 00 LB RE-HF MPAF 00 LB PRR MPAF 00 LB PS MPAF 05 LB DY MPAF 5/9 LB RE MPAF 22 CB MPAF 27 LB DYM MPAF 30 LB RE MPAF 30 LB RE-HF MPAF 30 LB HF-B MPAF 30 LB PS MPAF 3 LB RE MPAF 32 LB RE MPAF 33 LB RE MPAF 36 LB RE MPAF 36 LB LVM MPAF 40 LB RE MPAF 4 LB AB MPAF 52 LB PS * MPAF 55 LB PS * H Rail Shoes Drilling On Guard Rails TYPE OF RAIL H (inches) 00 LB ARA-B 2 /4 2/5/9 LB RE 2 5/8 5 LB-RE /32 32 LB RE 3 9/32 36 LB RE 3 /4 Rail Shoe (Using DBG-GR clamp) MPAF 00 LB ARA-B GR MPAF 5/9 LB RE GR MPAF 5 LB-RE-332 MPAF 32 LB-RE-3932 MPAF 36 LB-RE-34 H Rail Shoes Drilling On Girder Rails TYPE OF RAIL H (inches) 28/49 LB 3 28/49 LB 2 3/4 49 LB 2 3/4 GGR 8 2 3/8 RI60/RI60N 2.87 NP4A/NP4AM LB 2.87 Rail Shoe (Using DBG-LY clamp and 2 depth cutters) MPAF 28/49 LB GR MPAF 28/49 LB GR 234 MPAF 49 LB GR 234 MPAF GGR 8 MPAF RI 60 N MPAF NP4AM MPAF BA90

8 3.6) JOINT BAR POSITIONING GAUGES Positioning gauges MRF-Y... for drilling joint bar holes at pre-defined distances between rail end and holes center lines. POSITIONING GAUGE MRF Y0 MRF Y MRF Y2 MRF Y3 MRF Y4 MRF Y5 MRF Y6C A RAIL END HOLES DISTANCES (inch) A B C MRF Y0: suitable for drilling the following rails 00 ARA-B, 5 and 9 LB RE MRF Y: suitable for drilling the following rails 00 ARA-B, 05 DL&W MRF Y2: suitable for drilling the following rails 5, 9, 32, 36, 40 LB RE, 30 and 55 PS MRF Y3: suitable for drilling the following rails 80, 90 LB ASCE and 00 ARA-A MRF Y4: suitable for drilling the 85 LB ASCE rail MRF Y5: suitable for drilling the 30 LB RE and 36 LE.VAL rails MRF Y: universal positioning gauge for all rail sizes Note: other positioning gauge sizes available upon request. B 2 2/32" 7 /4" 5 /2" 3 /2" 6" 6" 2 2/32" 7 /4" 5 /2" 3 /2" 4 3/4" 4 3/4" 2 23/32" 6" 7" 3 /2" 6" 6" 3" 6" - 2 7/6" 5" - 2 7/6" 7" - 2 3/8" 7" - 2 3/4" 6 3/4" 6 3/4" 2 /6" 5 /2" 5 /2" 3 /2" 6" 6" C 4.2) Ordinary maintenance of the combustion engine Every 00 hours of operation 4.2.) Fuel filter cleaning (Ref. to Fig. 27) 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. Insert the fuel filter into the fuel tank and tighten the fuel filler cap securely. Improper use of solvents can result in fire or explosion. Every 3 months or 25 hours of operation 4.2.2) Air filter cleaning (Ref. to Fig. 28) 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. fuel filter FIG. 27 FUEL FILTER CLEANING A filter element FIG. 28 AIR FILTER CLEANING 7 28

9 4..2) Removal of metal residues from the crankcase When the drill is positioned as shown in Fig. 25 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. 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 holes, depending on the hardness of the rail. FIG. 25 REMOVAL OF METAL RESIDUES Every 50 hours of operating 4..3) Checking of screws. Check and re-tighten all screws where necessary. 4..4) Lubrication (Ref. to Figs. 32 and 33) Lubricate the spindle support housing by means of the appropriate lubricator (25), the screw of the DBG-Y clamping device. 4..5) Cleaning of coolant filter (Ref. to Fig. 26) 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 4mm key, unscrew the coupling (02). Extract the filter and clean it carefully. Reassemble the filter into the coupling (02) as shown in the Fig. 26, fully tighten the coupling. anti-impurity filter FIG. 26 Cleaning of COOLANT filter HOLE DIAMETER (inch) 7/8" 5/6" " /6" /8" 3/6" /4" 5/6" 3/8" 7/6" /2" 3/4" 7/8" 5/6 /6" /8" 3/6 /4" 5/6 3/8" 7/6" /2" 9/6" 3/4" 3/6" 7/8" 5/6" " /8" Broach cutter TSC /8" 538 TSC /4" TSC 5/6" TSC /2" TSC 3/4" PILOT bit Ref. PPC 2 Ref. PPL MAX. DEPTH OF CUT (inches) All the broach cutters allow automatic cooling by means of the SR5000 unit supplied with the drills. 7/8 " 2 " 3 " 27 8

10 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 holes, depending on the hardness of the rail. with adapter without adapter HOLE DIAMETER (inch) 9/32 3/8 /2 5/8 3/4 7/8 /2 3/4 7/8 /8 /4 SPIRAL BIT PE70 PE95 C PE30 PE60 PE90 PE220 PE30L-AR PE3/4 -L-AR PE7/8 -L-AR PE -L-AR PE-/8 -L-AR PE-/4 -L-AR APED... ADAPTER APED70 APED 3/8 Y APED 30 APED35/65 without adapter without adapter APED 30 without adapter without adapter without adapter without adapter without adapter SPACER included in the APED 70 included in the APED 3/8 Y included in the APED 30 included in the APED 35/65 DPE DPE included in the APED 30 DPE DPE DPE DPE DPE For tools of other types, check the dimensional compatibility (particularly the size of the attachment and the length). 3.9) "LR2" LubrocOOler concentrate, 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. 3.0) "LR3" antifreeze concentrate of or 5 gallons added to the lubrocooling mixture with the right percentage will maintain the lubrocooling mixture fluid in negative temperature consitions. Diam. Diam. ADDITIONAL ACCESSORIES not required not required not required not required not required not required TST50 + DBG-AY TST50 + DBG-AY TST50 + DBG-AY TST50 + DBG-AY TST50 + DBG-AY TST50 + DBG-AY LR 2 LR 3 Before you service or remove parts, stop the engine and allow it to cool. Always remove the cap from the spark plug when servicing the engine to prevent accidental starting. After the first 0 operating hours, proceed with sump oil change, as follows: (Ref. to Figs. 24 and 24a) Remove the cap with the magnetic insert (28). Remove the oil filler cap (07). Make sure that all the oil comes out by tilting slightly the drilling machine in order to make the operation easier. Clean the cap (28) (see 4..2). 07 Reassemble the cap. Fill the oil sump to the level indicator (see 4..) using the oil supplied with the drilling machine; it will be necessary to use about 00 ml oil. Replace the oil filler cap (07). Ensure that disposal of used oil is in accordance with current legislation. 4.) Ordinary maintenance of the drill Every 20 hours of operation 4. MAINTENANCE 4..)Topping up oil (Ref. to Figs. 24 and 24a) 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 (9). 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. Never use regenerated or used oil. The oil must be clean. FIG. 24 FIG. 24a

11 3. STORAGE 4. SR5000 COOLANT UNIT (Ref. to Fig. 3) When work has been completed, put away the drill by proceeding as follows: 3.) Depressurise the tank of the SR 5000 coolant unit (see 4), close the tap (02) on the tube from the tank, and disconnect the quick-coupling (03). 3.2) Carefully clean the drill, particularly in the spindle area, removing machining waste (swarf, etc.) and any deposits of lubricating coolant. 3.3) Fully withdraw the spindle. 3.4) Place the drill and the SR5000 coolant unit in a sealed place free from dust, moisture and the risk of accidental impact. For better protection Cembre recommends the use of the VAL LD metal case designed for this purpose (see 3.3). The DBG-Ymoving 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 case containing the most commonly used accessories. The type SR5000 coolant unit (0) consists of a tank complete with tube and maximum pressure valve, 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 0 Tank complete with hose and max. pressure valve 02 Tap 03 Quick-coupling 7 Vent valve 35 Attachment valve 0 VAL MPA LD-4PY 02 VAL LD FIG. 23 STORAGE CASE FIG. 3 COOLANT UNIT

12 @ The drill is equipped with a coolant attachment valve (35) and a vent valve which are located as shown (Fig. If under certain operating circumstances they need to be interchanged, as Using a 7 mm hexagonal spanner unscrew the vent valve from its Using the 4 mm allen key provided with the drill, remove the appropriate valve from its seat and fit into the vent valve Fit the vent valve into the into the vacant coolant valve When temperatures fall below 32 F (0 the lubrocoolant may freeze could cause damage to the contained in the drill coolant It is therefore advisable, when the drilling machine, to empty lubrocoolant system Proceed as follows (Fig. 4): Disconnect the quick coupling 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. FIG. 4 4.) 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 2. CHECK FUEL WARNING - Gasoline is extremely flammable and explosive. - Stop engine before refueling. - Do not smoke. - Refuel in a well ventilated area away from flame or sparks. - Stop engine and allow to cool before refueling. - Exhaust gas contains carbon monoxide, an odourless and deadly poison. - Do not run the engine in an enclosed area. - To avoid a serious burn, do not touch a hot engine or muffler. - The engine becomes hot during operation. The LD-4PY drilling machine features a 4-CYCLE gasoline engine run on unleaded regular gasoline only. Pump octane rating 86 or higher. For refuel proceed as follow: Check the fuel level by looking through the translucent fuel tank. Stop the engine and open the fuel cap, if the engine has been running, allow it to cool. 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. TAPPO FUEL FILLER SERBATOIO CAP LIVELLO MAXIMUM SUPERIORE FUEL LEVEL FUEL FILLER CAP FIG. 5 ARE ADAPTOR 24

13 . START ENGINE 5. SPINDLE ADVANCE LEVER (Ref. to Fig. 6) Before starting the engine, ensure that: - the spindle shaft is fully retracted. - the accelerator control lever is positioned at the low speed position..) Set the engine ON/OFF switch to the ON position (Fig. a)..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)..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)..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..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)..6) Keep the engine warming up for at least 3 minutes before starting any actual drilling..7) To stop the engine, set the accelerator lever at the low speed position and allow the engine to run at low speed for 2 or 3 minutes before stopping. Set the ON/OFF switch to the OFF position. a) b) c) 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 6b - With the release pawl (39) pressed, the lever is released from its hub and can repeat the previous travel without the spindle moving. 36 6a - Moving the lever (36) towards the operator produces a corresponding advance of the spindle. 6c - With the hub released, moving the lever towards the operator produces a corresponding advance of this spindle. NOTICE: the engine will perform at its optimum after a running-in period of approximately 200 drilling operations. d) e) 5.) 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). FIG

14 6. PREPARING THE DRILL 9. EXAMPLE OF SPECIAL RAIL DRILL APPLICATIONS 6.) Assembling broach cutters (Ref. to Figs. 8-). 6..) Insert the pilot bit in the cutter from the side of the spigot. 6..2) Using the lever (36), position the spindle shaft (07) so that both grub screws (8) 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 (7) (see Fig. ). 6..3) Insert the cutter in the spindle shaft so that the two engaging dogs on the cutter spigot line up with the grub screws (8). 6..4) Clamp the cutter by fully tightening the grub screws by means of the 4 mm male hexagon key. 6..5) Check that the guide bit slides freely by applying slight pressure on it. Engaging dogs Short type broach cutter Maximum drilling thickness: inch Use on girder rail (Ref. to Fig. 2 a-b, example for 28 GR or GGR 8) FIG. 2a Side DBG-LY over rail clamp and the specific shoes (combination) allows the positioning on both sides of the rails. Use of 2" depth of cut broach cutters FIG. 2b Side Pilot bit PP... Use on running rails (Ref. to Fig. 22) (narrow passage of the articulated arm) DBG-GR over rail clamp equipped with TDB termination FIG. 22 FIG. 8 ASSEMBLING BROACH CUTTERS Pilot bit PPL... Long type broach cutter Maximum drilling thickness: 2 inches 0. SPECIAL APPLICATIONS FOR Cembre RAIL DRILLS 6.2) Assembling spiral bits (Ref. to Figs. 9 - ) 6.2.) 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. ). MPAF 85 LB ASCE = Application developed for narrow chairs * = 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 3 22

15 Approach Start drilling with discharge of lubrocoolant 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 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 35/65) 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. 0) ) Clamp the bit by fully tightening the two grub screws(8) using the 4 mm male allen key. Drilling 8 DPE * APE... Bits PE... (e.g. PE70) Finish drilling with removal of swarf and switching off of lubrocoolant 07 FIG. 9 COOLANT DRILLING WITH BROACH CUTTER DPE Bits PE... (e.g. PE 90) 8.3) Drill fitted with special spiral bit Follow the sequence described in ( 8.), 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), (see 4) before starting to drill, then switched off after drilling by closing the tap. * use only for APE, not required for APED FIG. 9 ASSEMBLING SPIRAL BITS FIG. 0 ASSEMBLING THE BIT-SPACER UNIT DPE spacer APE adapter Spiral bit 7 33 FIG. 20 COOLANT DRILLING WITH SPIRAL BIT FIG. MANUAL SPINDLE ROTATION 2 4

16 7. RAIL DRILL TYPE LD-4PY Ref. LD-4PY consist of the LD-4PNY basic drill (see page 2) complete with the DBG-Y moving arm device for clamping to the rail web and the track fittings (Refer to Fig. 2). The DBG-Y clamping device consists of: Clamping unit Type TDB6 standard termination. Socket head cap screws M8x25 (2 pcs). Spring washers (4 pcs). Reference rod. 8..4) Start the engine, following instructions on. 8..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. 8..6) The pilot bit will enable the lubrocoolant to be discharged throughout the drilling process. 8..7) When drilling has been completed, fully retract the spindle, stop the motor by pressing the switch to "OFF" position, and make sure that drilling swarf is removed before recommencing drilling. 8..8) After drilling it is advisable to remove with the brush all swarf from the tool and spindle area. 8.2) Drill fitted with long type broach cutter (for drilling thicknesses of up to 2"). Follow the sequence described in 8., taking care to position the drill on the rail by keeping the spindle fully withdrawn. 36 reference rod 02 TDB 6 M 8x25 screws and spring washers FIG. 2 DRILL WITH DBG-Y CLAMPING DEVICE FIG. 8 DRILLING 5 20

17 <> 8. DRILLING (Ref. to Figs. 7-8) Check engine oil level before operation (see 3.2.4) Switch on the cooling system before starting the drill (see 4) 8.) Drill fitted with short type broach cutter (for drilling thicknesses of up to "). The drilling sequence may be started with the drill fitted with the broach cutter ( 6.), clamping termination ( 7.), positioning shoe ( 7.3), the drill being clamped to the rail ( 7.4), as follows: 8..) Connect the female quick-coupling of the SR5000 coolant unit to the male coupling (35) on the drill. 8..2) Open the tap (02) fitted on the coolant unit hose. 8..3) Using the lever (36) bring the guide bit almost in contact with the rail (Fig. 7a); keeping the release pawl (39) Fig. 7a pressed, release the lever from its cup and return into the initial position (Fig. 7b), which will enable the travel of the lever (36) to be used in the most advantageous way ) Assembling of the termination of the DBG-Y device with moving arm for clamping the drill to the rail web and track fittings. 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 fittings; their assembly is shown in Fig. 3. When disassembling the TDB 6 termination ensure that, after removing the pivot, the complete assembly is slid away downward without acting on the holding plate. holding plate FIG. 7 DRILLING Fig. 7b Fig. 7c FIG. 3 ASSEMBLY OF THE TERMINATION ) Assembly of the DBG-Y clamping device on the drill The DBG-Y 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

18 35 DBG-Y Clamping device FIG. 4 ASSEMBLY OF DBG-Y CLAMPING DEVICE 7.4) Clamping to the rail web (Ref. to Fig. 6) The special shape of the positioning shoes, each corresponding to the type of rail, enables the drill to be positioned quickly, accurately and safely on the element to be drilled. To position the drill, complete with the clamping termination ( 7.) and the positioning shoe ( 7.3) suitable for the type of rail to be drilled, proceed as follows: 7.4.) Withdraw the spindle shaft (07) completely by means of the lever (36) ) Bring the moving arm (03) of the clamping device into the fully open position by means of the handwheel () ) Place the drill on the rail at the point where the drilling is to be carried out, and clamp it by tightening the handwheel () right down: the positioning shoe will automatically position the cutter or spiral bit in line with the desired axis; if accurate positioning relative to the longitudinal axis of the rail is required, use the reference rod (8). Rail drill front plate 7.3) Assembly of positioning shoes (Ref. to Fig. 5) 7.3.) The type MPAF.. and MPAU positioning shoes are secured to the front plate (22) of the drill by means of the two socket head cap screws M 6x6 supplied reference pin MPAU MPAF... screws M6x6 FIG. 5 ASSEMBLY OF POSITIONING SHOES FIG. 6 POSITIONING OF THE DRILL 7 8