Cembre LD-16B Manual

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RAIL DRILL
LD-16B - LD-16BA - LD-16BE - LD-16BT
ENGLISH
ĞƌƟĮĞĚŶǀŝƌŽŶŵĞŶƚĂů
DĂŶĂŐĞŵĞŶƚ^LJƐƚĞŵ
ĞƌƟĮĞĚKĐĐƵƉĂƟŽŶĂů
,ĞĂůƚŚΘ^ĂĨĞƚLJ
DĂŶĂŐĞŵĞŶƚ^LJƐƚĞŵ
ĞƌƟĮĞĚYƵĂůŝƚLJ
DĂŶĂŐĞŵĞŶƚ^LJƐƚĞŵ
OPERATION AND MAINTENANCE MANUAL
16 M 187 E

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INDEX page
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 ......................................................................................................................................... 16
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. Return to
Cembre for overhaul............................................................................................................................... 35
Appendix “A”............................................................................................................................................................................... 35

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ATTENTION
– 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.
– 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.
– 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.
– The degree of protection of the drilling machine against moisture is classified “ordinary"
(EN 50144-1 Standard).
Do not expose the drill to rain and moisture; any water ingress may damage the electric motor,
circuit board and battery.
– Batteries are supplied with a charge ≤ 30%.
To maximise energy level, it is necessary to fully recharge them before use.
Protect the batteries from humidity!
Do not expose the batteries to fire!
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.
Do not use defective or deformed batteries! DANGER OF EXPLOSION OR FIRE!
Do not open batteries!
Do not touch or short-circuit the battery contacts!
A slightly acidic and flammable liquid may leak from defective Lithium batteries!
If this liquid comes into contact with skin, rinse immediately and thoroughly with water.
If the liquid from the battery comes into contact with the eyes, rinse with clean water and seek
medical advice immediately.

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Definitions:
LD-16BN LD-16BNA
LD-16BNE LD-16BNT
(drill without railweb clamping device)
LD-16B LD-16BA
LD-16BE LD-16BT
(drill complete with
DBG-F2 railweb clamping device)
USER INFORMATION in accordance with “Directives 2011/65/EU e 2012/19/EU regarding the re-
duction of hazardous substances in electrical and electronic equipment, including the disposal
of waste”.
The ‘Not in the bin’ symbol above when shown on equipment or packaging means that the equipment must, at
the end of its life, be disposed of separately from other waste.
The separate waste collection of such equipment is organised and managed by the manufacturer. Users wishing
to dispose of such equipment must contact the manufacturer and follow the prescribed guidelines for its separate
collection.
Appropriate waste separation, collection, environmentally compatible treatment and disposal is intended to re-
duce harmful environmental effects and promote the reuse and recycling of materials contained in the equip-
ment.
Unlawful disposal of such equipment will be subject to the application of administrative sanctions provided by
current legislation.
- Following information applies in member states of the European Union:

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11
2
34
5
6
7
8
9
10
11
12
14
13 15
16
17
1Powerful LED worklights
2Spindle advance lever
3Battery 36V Li-Ion
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 LED worklights ON / OFF switch
17 Air valve
Descriptions: FIG. 1

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LD-16B LD-16BE LD-16BT LD-16BA
Rated drilling capacity Ø mm (inch)
7 33 (9/32) (1 5/16)
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 20
Weight (drilling machine only) kg (lbs) 13,7 (30.1)
Weight (with DBG-F2 and battery) kg (lbs) 18,5 (40.7)
Dimensions Ref. to page 38
Operating temperature °C (°F) -15 to +40 (+5 to +104)
Recommended oil (100 ml)
(for gear sump) type SHELL SPIRAX S4 TXM SAE 10W-30
Air Noise (1) dB LpA 83,8 (A) LpCPeak 103,9 (C) LWA 90,7 (A)
Vibrations (2) m/s21,6 max.
Rechargeable battery type CB3662L (Li-Ion)
Voltage / Current / Energy V / Ah / Wh 36 / 6.2 / 223.2
Weight kg (lbs) 1.6 (3.5)
Battery charger ASC ULTRA type EU
27265000
UK
27266000
AUS/NZ
Ref. to note 3
USA/CAN
627268000
Input V / Hz (W) 220 - 240 / 50 - 60 (290) 115 / 60 (290)
Output V / A 14.4 - 36 / 6.5 max.
Weight kg (lbs) 0.97 (2.1)
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
Weightedrootmeansquareinfrequencyof theaccelerationtheupperlimbsareexposedto 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.
(3) Type ASC30-36 27047000: 220 - 240 V 50 - 60 Hz 85 W(3) Type ASC30-36 27047000: 220 - 240 V 50 - 60 Hz 85 W
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 CB3662L rechargeable battery (2 pcs)
36 V 6,2 Ah (LiHD Technology) Li-Ion, equipped with LED indicators
of the remaining battery life at any time by pressing the button.
2.13) ASC Ultra -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 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
applicationofelectricalconnectionsandforadditional special applications.
– TDB 6: standard termination for rails and stock rails.
(*) Already supplied with LD-16B ; LD-16BA ; LD-16BE ; LD-16BT rail drills
TDB 7
3.1.1) DBG-LF2 device
with moving arm complete withTDB 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
For clamping the drill to flange rails, for use in
conjunction 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
accessories.
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
accessories.
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.