Cembre LD-16B-RP User manual

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RAIL DRILLRAIL DRILL
LD-16B-RP LD-16B-RPA LD-16B-RPE LD-16B-RPT
OPERATION AND MAINTENANCE MANUAL
(Translation of the original instructions)
ENGLISHENGLISH
22M051E_0423_6261424

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INDEX page
WARNING .................................................................................................................................................................................................. 3
Compliance of use ................................................................................................................................................................................. 4
1. General characteristics............................................................................................................................................................. 6
2. Accessories supplied with the drill ...................................................................................................................................... 7
3. Accessories to be ordered separately ................................................................................................................................. 9
4. Spindle advance lever .............................................................................................................................................................. 13
5. Motor ON/OFF switch (EMERGENCY) ................................................................................................................................. 14
6. LED worklights ON/OFF switch............................................................................................................................................. 14
7. LED indicator................................................................................................................................................................................ 15
8. "Drilling assistance" function................................................................................................................................................. 15
9. Rechargeable battery ............................................................................................................................................................... 16
9.1) Using the battery charger ....................................................................................................................................................... 17
10. SR5000 coolant unit ................................................................................................................................................................. 17
11. Preparing the drill ...................................................................................................................................................................... 19
11.1) Assembling broach cutters with Quick push/turn shank............................................................................................ 19
11.2) Assembling broach cutters with Weldon shank.............................................................................................................. 20
11.3) Assembling spiral bits............................................................................................................................................................... 21
11.4) Assembling terminations on DBG-F2 clamping device ............................................................................................... 22
11.5) Assembly of DBG-F2 clamping device................................................................................................................................ 23
11.6) Fitting positioning templates .............................................................................................................................................. 23
11.7) Fitting "double sided" templates......................................................................................................................................... 24
11.8) Clamping the drill to the rail web......................................................................................................................................... 25
12. Drilling operation....................................................................................................................................................................... 26
12.1) Drill fitted with broach cutter ................................................................................................................................................ 26
12.2) Drill fitted with spiral bit.......................................................................................................................................................... 28
13. Alarms............................................................................................................................................................................................. 29
14. SPA positioning plate................................................................................................................................................................ 30
15. Storing the drill ........................................................................................................................................................................... 32
16. Maintenance ................................................................................................................................................................................ 33
17. Navigation menu ....................................................................................................................................................................... 36
18. Display alarms ............................................................................................................................................................................. 37
19. Return to CEMBRE for overhaul............................................................................................................................................... 38
Appendix “A”............................................................................................................................................................................................. 38

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– Before using the rail drill, carefully read the instructions contained in this manual.
SAVE THESE INSTRUCTIONS: this manual contains important safety and operating instructions
for the rail drill.
– Do not use the rail drill for purposes other than those intended by CEMBRE.
– Never use a rail drill that is faulty, has been tampered with or which has been modified from its
original form.
– Degree of protection IP44M regarding the ingress of water into the motor and /or battery applies
only when the battery provided and rainproof cover are correctly used together.
Before use, always check:
• The precise positioning of the rainproof cover, especially around the battery area.
• The integrity of the rainproof cover, for example, the absence of cuts or abrasions; a damaged
cover must be replaced in order to avoid ingress of water and moisture into the motor and / or
the battery.
– When operating, stand in a stable, secure position and grip the drill firmly.
Be sure to work in good light conditions or with sufficient artificial lighting.
During drilling keep your hands outside the danger area.
Always wear protective glasses and working gloves.
Avoid wearing clothes which may present a risk to personal safety.
– Always remove the battery when servicing the drill, before performing any work in the area of
the spindle e.g removing cutting tools (broach cutters, spiral bits) assembling positioning tem-
plates, maintenance or cleaning.
Safety instructions for batteries:
– Protect battery from water and moisture!
– Do not expose batteries to naked flames!
– Do not use faulty or deformed batteries!
– Do not open batteries!
– Do not touch or short circuit battery contacts!
– A slightly acidic, flammable fluid may leak from defective Li-ion
batteries!
– If battery fluid leaks out and comes into contact with your skin,
rinse immediately with plenty of water. If battery fluid leaks out
and comes into contact with your eyes, wash them with clean water
and seek medical attention immediately!
– At the end of their life, always recycle batteries.
– Never discard batteries with domestic waste. They must be sent
to appropriate collection centres for disposal.
– If the machine is defective, remove the battery from the drill.
– Remove the battery from the machine to transport the machine.
– For transportation of Li-Ion batteries please refer to page 38.
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WARNINGS

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Definitions:
LD-16BN-RP LD-16BN-RPA
LD-16BN-RPE LD-16BN-RPT
(Rail drill without railweb clamping device)
LD-16B-RP LD-16B-RPA
LD-16B-RPE LD-16B-RPT
(Rail drill complete with DBG-F2 railweb
clamping device)
Compliance of use
– The device is a battery drilling machine intended for use in Railway applications to provideconsistent and accurate
holes in various rail types and railtrack equipments.
Any other use, or use deemed to be outside of the specification of the device shall be regarded as improper
use. In these instances the manufacturer/supplier shall not be liable for any damage resulting from improper use
and the user agrees to bear all risk.
– The device is manufactured in accordance with current technological standards and recognized safety rules.
However, danger to life and limb of the user or third parties/or damage to the device and other tangible assets
can arise during use.
– The device may only be used for its intended purpose and if in perfect working order, and it must be used
with appropriate consideration given to the safety and danger warning messages stated in the operating manual.
– Usage of the device for its intended purpose also incorporates compliance with the operating manual, including
the manufacturer‘s maintenance recommendations and specifications.

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1 1
2
34
5
6
7
8
9
10
11
12
14
13 15
17
20
1Powerful LED worklights
2Spindle advance lever
3Rechargeable 36V Li-Ion battery
4Trasport handle
5Oil filler cap
636V DC motor unit
7Oil level indicator
8Coolant connection
9Cap with magnetic insert
10 Lubricator for spindle shaft
11 Front plate for assembling templates
12 Spindle shaft
13 Support handgrip
14 LED indicator
15 Motor ON / OFF switch (EMERGENCY)
16 Silicone rainproof cover
17 LED worklights ON / OFF switch
18 OLED Display
19 Capacitivetouchbuttonformenuselection
20 Air valve
Descriptions: FIG. 1
16
18
19

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LD-16B-RP LD-16B-RPE LD-16B-RPT LD-16B-RPA
Rated drilling capacity
Ø mm
(inch)
7 33 (9/32) (15/16)
7 13 (9/32) (1/2) with CEMBRE PE range spiral bits
13 33 (1/2) (1 5/16) with CEMBRE CY range broach cutters
Max drilling thickness
mm (inch) 50 (2)
Rated no load speed n0 (spindle)
min-1
260
Brushless electric motor V 36
Degree of protection (motor-battery) IP 44M (EN 60529 Standard)
Weight (drilling machine only) kg (lbs) 14,1 (31)
Weight (with DBG-F2 and battery) kg (lbs) 19,2 (42.2)
Dimensions Ref. to page 38
Operating temperature °C (°F) -20 to +50 (- 4 to +122)
Recommended oil (100 ml)
(for gear sump) type SHELL SPIRAX S4 TXM SAE 10W-30
Air Noise (1) dB LpA 77,3 (A) LpCPeak 98,3 (C) LWA 89,2 (A)
Vibrations (2) m/s2ah 1,21 max.
Rechargeable battery type CB3680L (Li-Ion)
Voltage / Current / Energy V / Ah / Wh 36 / 8.0 / 288
Weight kg (lbs) 1.9 (4.2)
Battery charger type ASC145-
EU
ASC145-
UK
ASC145-
AUS/NZ
ASC145-
USA/CA
Input V / Hz (W) 220 - 240 / 50 - 60 (190) 115 / 60 (190)
Output V DC / A 10,8 - 36 / 8 max.
Weight kg (lbs) 0,6 (1.32)
In order to optimise the charge of the battery, the drill is equipped with a timer which disconnects power to
the motor when the continuous operating time threshold of 120 s has been exceeded.
(1) Directive 2006/42/EC, annexe 1, point 1.7.4.2 letter u
LpA = weighted continuous acoustic pressure level equivalent.
LpCPeak = maximum value of the weighted acoustic displacement pressure at the work place.
LWA = acoustic power level emitted by the machine.
(2) Directive 2006/42/EC, annexe 1, point 2.2.1.1
Weighted rootmeansquareinfrequencyoftheaccelerationtheupperlimbsareexposedto for each biodynamicreference
axis. Tests carried out in compliance with the indications contained in EN ISO 5349-1/2 Standard, and under operating
conditions much more severe than those normally found.
1. GENERAL CHARACTERISTICS

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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.
PPL 2 (1 pc) diameter 8 mm.
2.2) Spacer, type DPE, (1 pc) for controlling the coolant system, use with APE adapter for
special spiral bits.
2.3) Adapter, type ARE (1 pc) for external coolant connection, use with SR5000
coolant unit.
2.4) Grub screw, M8x10 (1 pc as a spare) for securing broach cutters or spiral bits
with Weldon shank on spindle shaft.
2.5) Transverse threaded pin (1 pc as a spare) for securing broach cutters or spiral bits
with push/turn shank on spindle shaft.
2.6) Wing nuts (2 pcs) complete with fixing washer for securing positioning inserts
type KPAF to front plate.
2.7) Screws M6x16 (4 pcs) for securing positioning templates to front plate.
2.8) Screws M6x25 (4 pcs) for securing special positioning templates type MPD... & MPR...
to front plate.
2.9) Range of tools:
5 mm Allen key (1 pc)
6 mm Allen key (1 pc)
4 mm T-handle Allen key (1 pc)
Brush (1 pc)
2.10) 100 ml oil bottle for gear sump.
Ref. to §16 for other details.
(Parts 2.1 to 2.10 are included in the "ACCESSORIES KIT ", Code Nr. 6004356)
2. ACCESSORIES SUPPLIED WITH THE DRILL

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2.11) Type SR5000 coolant unit (1 pc)
Provides coolant fluid to the cutter during the drilling operation.
Consists of a tank complete with tube and maximum pressure valve,
fitted with a pump device for pressurisation.
2.12) Type CB3680L rechargeable battery (2 pcs)
36 V 8,0 Ah (LiHD Technology) Li-Ion, equipped with LED indicators
of the remaining battery life at any time by pressing the button.
2.13) ASC 145 -fast charger (1 pc)
Differs depending on geographic region.
Use to quickly charge the Li-Ion batteries supplied:
- Minimal current consumption in stand-by mode
- Management of the charging process by means of a processor
- “AIR COOLED”function for quicker cooling of the battery in case
of overheating.
2.14) Canvas bag type CVB-032 (1 pc)
Designed to store and protect the batteries and the battery
charger.
Can be separated into two parts for easy storage inside the drill case.
Optimal battery storage temperature is between 10°C and 30°C.

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TDB 1 TDB 6 TDB 3
3.1) DBG-F2 device (*) with moving arm for clamping the drill to the rail
web and track fittings, complete with the following terminations:
– TDB 1: for switch blades and compound frogs.
– TDB 3: for repairing (adjusting) existing holes on rails for subsequent ap-
plication of electrical connections and for additional special applications.
– TDB 6: standard termination for rails and stock rails.
(*) already supplied with LD-16B-RP LD-16B-RPA LD-16B-RPE LD-16B-RPT drill type.
TDB 7
3.1.1) DBG-LF2 device
with moving arm complete with TDB 7 termination
for clamping the drill to girder rails and for additional
special applications.
3.3) VAL P24 plastic carrying case for storing the drill complete with the DBG-F2 and drilling accessoires.
VAL P24-CS wheeled plastic carrying case: VAL P24 with folding handle and wheels.
3.3.1) VAL LD-L metal case for storing the drill complete with the DBG-LF2 device, DBSN device and VAL MPA
tool case.
VAL LD-L
VAL P24-CS
3.2) DBSN device
Forclamping the drilltoflangerails, for use in conjunc-
tion with the MPAF templates.
Using this device the rail drill can remain clamped
in the drilling position even when trains pass over it.
3. ACCESSORIES TO BE ORDERED SEPARATELY

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3.4) MPAF templates for positioning the drill on rails and stock rails
to enable drilling to be carried out according to the provisions of
railway boards standards e.g.:
– MPAF UIC54 on DRILLING AXIS of 54E1 rail
– MPAF UIC60 on DRILLING AXIS of 60E1 rail
• Contact CEMBRE for selection of other specific application ac-
cesories.
3.5) MPAU universal positioning template suitable for
repairing existing holes on various fittings, and for drilling
disused rails.
3.6) KPAF "double sided" templates with double face, enable
drilling on two types of rails with a single kit, simply by turning the
two inserts.
• Contact CEMBRE for selection of other specific application acces
sories.
3.7) SPA positioning plates for use in conjunction
with MPAF... positioning templates.
For drilling rail heads with a centre-to-centre
distance established in the Railway boards stan-
dards, without the need for marking out;
• Contact CEMBRE for selection of other specific
application accessories.
3.8) 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.
3.9) VAL-MPA tool case for storing
the accessories indicated in 3.4 - 3.8, and the
cutting tools.