Cembre LD-1PY-ECO User manual

1
RAIL DRILL
RAIL DRILL
LD-1PY-ECO
ENGLISH
ENGLISH OPERATION AND MAINTENANCE MANUAL
12M007U - 6261140

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Ref. LD-1PNY-ECO:
basic drill without clamping device
(Fig. 1).
Ref. LD-1PY-ECO:
(LD-1PNY-ECO + DBG-Y)
basic drill complete with
railweb clamping device
type DBG-Y (Fig. 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.
– 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.
FIG. 1
FIG. 2

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1. GENERAL CHARACTERISTICS
– Drilling capacity:................................................................................................................ 9/32" to 1 9/16"
(with special twist drill bits: hole diameters of 9/32" to 1-1/8" on rails up to 3 1/2" thick)
(with broach cutters: hole diameters of 3/4" to 1-9/16" on rails up to 2 3/4" thick)
– Speed without load:...................................................................................................................... n° 270 rpm
– Combustion engine:
Type:..............................................................Forced air cooled, 2 cycle, horizontal shaft, single cylinder
Model:............................................................................................................................................KAWASAKI TJ45E
Displacement:............................................................................................................................................. 45.4 cm3
Power (SAE J1349):.................................................................................................1.4 kW (1.9 hp) / 7500 rpm
Fuel tank capacity: ...........................................................................................................0.24 US gal (0.9 litres)
Clutch:.............................................................................................. centrifugal with automatic intervention
Starter:..........................................................................................................recoil sarter (with spring damper)
Ignition:..............................................................................................................solid state ignition (C.D.I. type)
Spark plug:............................................................................................................NGK BPMR7A or equivalents
Fuel:................................................................................................. 2% (1:50) oil/gasoline mixture (see § 12)
Fuel consumption: .................................................................................................. 470 g/kW.hr / 350 g/hp.hr
Emissions:................................................... according to "Phase 2" EPA regulation engines class V and
European Directives 97/68/EC, 2001/63/EC and 2002/88/EC
– Weight:.......................................................................................................................................................34.5 lbs
– Weight: with “DBG-Y” clamping device ........................................................................................41.5 lbs
– Gear sump:
Recommended oil:........................... MOBIL SUPER MULTIGRADE 10-30-SAE or
ESSO UNIFARM 10 W 30 or equivalent
–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............................................................................................. 99.5 dB (A)
– The maximum value of the weighted acoustic displacement
pressure C at the work place LpCPeak is equal to....................................................................116.3 dB (C)
– The acoustic power level emitted by the machine
LWA is equal to..................................................................................................................................107.6 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 Standard
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
4.36 m/sec2 max.

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2. ACCESSORIES SUPPLIED WITH THE DRILL
2.1) Pilot bits for controlling the cooling system:
for use with short broach cutters (7/8 " depth of cut)
– 1 pc PPC 2
for use with long broach cutters (2 " depth of cut)
– 1 pc PPL 2
2.2) Spacer, type DPE, for use with spiral bits and APE adaptor
for controlling the cooling system.
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 shoes to front plate.
2.6) Socket head cap screws, M6x25
– 4 pcs for securing special positioning shoes 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
2.8) 3.4 fl oz (100 ml) oil bottle
for gear sump.
(Accessories from pos. 2.1 to pos. 2.8 are
included in the “Kit of accessories” having
the code 6001904)
2.9) Type SR5000 cooling unit

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3. OPTIONAL ACCESSORIES (to be ordered separately)
3.1.1) "DBG-LY" device specific for clamping the drill to the
girder rails (for example 128 GR or GGR 118, Ri60).
With the specific shoes allows the positioning on both sides of
the rails, complete with the TDB 3 termination.
3.1) "DBG-Y" devicewith moving arm for clamping the drill
to the rail web and track fittings, complete with the TDB 6
termination.
This device is supplied with the drill type LD-1PY-ECO
3.1.2) "DBG-GR" device for clamping the drill in correspondance of guard
rail, complete with the TDB 1 termination.
This device is supplied with the drill type LD-1PYGR-ECO.
3.1.3) DBSN device for clamping the drill to flange
rails, for use in conjunction with the MPAF rail shoes.
Using this device the rail drill can remain clamped in
the drilling position even when trains pass over it.
TDB 6
TDB 3
TDB 1

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3.3) “VAL LD”steel carrying case for accom-
modatingthe completedrillwith theclamping
device.
22 1/2" (L) x 13 1/2" (W) x 17 1/2" (H)
3.5) "MPAU" UNIVERSAL RAIL SHOE for rail or for special
applications such as drilling #20 high speed switch points
(positioning not automatic).
3.5.1) ."MPAU10" UNIVERSAL SHORT RAIL SHOE
forrailorforspecial applications (positioning not automatic).
3.2) "TST 50" two stage template
(to be used with specific DBG-AY clamp)
This device enables the drilling of 150 lb and
aluminium composite contact rails from one side.
Restart of work stroke: 1,97”
Typical application:
– . Aluminium composite rail.
– . 150 lbs contact rail.
3.4) “VALMPA”suitableforstorage ofrailshoes,cutters
and accessories
• 15 1/2” (L) x 13 3/4” (W) x 2 1/4”(H)

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3.5.2) ."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 SHOES DRILLING ON GUARD RAILS
RAIL SHOES DRILLING ON RUNNING RAILS
RAIL SHOES DRILLING ON GIRDER RAILS
H
H
(*) to be used with PFA 1 arbour extension and PPL5 Pilot Bit.
100 LB ARA-B 2 1/4”
112/115/119 LB RE 2 5/8”
115 LB-RE-3132 3 1/32”
132 LB RE 3 9/32”
136 LB RE 3 1/4”
MPAF 100 LB ARA-B GR
MPAF 115/119 LB RE GR
MPAF 115 LB-RE-3132
MPAF 132 LB-RE-3932
MPAF 136 LB-RE-314
RAIL SHOE
(Using DBG-GR clamp)
TYPE OF
RAIL
H
inches
128/149 LB 3”
128/149 LB 2 3/4”
149 LB 2 3/4”
GGR 118 2 3/8”
RI60/RI60N 2.87”
NP4A/NP4AM 2.87”
180-105 LB 2.87”
MPAF 128/149 LB GR
MPAF 128/149 LB GR 234
MPAF 149 LB GR 234
MPAF GGR 118
MPAF RI 60 N
MPAF NP4AM
MPAF BA9101
TYPE OF
RAIL
H
inches
RAIL SHOE
(Using DBG-LY clamp
and 2” depth cutters)
40 LB ASCE 3 1/16"
60 LB ASCE 3 1/16"
80 LB ASCE 2 3/16”
85 LB ASCE 2 17/64”
85 LB PRR 2 1/16”
85 LB PS 2 15/64”
90 LB ARA-A 2 9/16”
90 LB ASCE 2 45/128”
100 LB ARA-A 2 3/4”
100 LB ARA-B 2 65/128”
100 LB ASCE 2 65/128”
100 LB DY 2 5/8”
100 LB NYNH&H 2 39/64”
100 LB RE 2 45/64”
100 LB RE-HF 2 45/64”
100 LB PRR 2 9/32”
100 LB PS 2 31/64”
105 LB DY/110 LB RE 2 43/64”
112/115/119 LB RE 2 7/8”
122 CB 2 7/8”
127 LB DY 3 1/8”
130 LB RE/HF-A 2 3/4”
130 LB RE-HF 3 1/16"
130 LB HF-B 3 3/8”
130 LB PS 2 3/4”
131 LB RE 3 1/2”
132 LB RE 3 3/32”
133 LB RE 3”
136 LB RE 3 3/32”
136 LB LE VAL 3 1/16”
140 LB RE/140 PS 3”
141 LB AB/ 141 LB RE 3 3/32”
152 LB PS 3 3/4”
155 LB PS rail 3 3/8”
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 100 LB ARA-A
MPAF 100 LB ARA-B
MPAF 100 LB ASCE
MPAF 100 LB DY
MPAF 100 LB NH
MPAF 100 LB RE
MPAF 100 LB RE-HF
MPAF 100 LB PRR
MPAF 100 LB PS
MPAF 105 LB DY
MPAF 115/119 LB RE
MPAF 122 CB
MPAF 127 LB DYM
MPAF 130 LB RE
MPAF 130 LB RE-HF
MPAF 130 LB HF-B
MPAF 130 LB PS
MPAF 131 LB RE
MPAF 132 LB RE
MPAF 133 LB RE
MPAF 136 LB RE
MPAF 136 LB LVM
MPAF 140 LB RE
MPAF 141 LB AB
MPAF 152 LB PS *
MPAF 155 LB PS *
TYPE OF
RAIL
H
inches
RAIL
SHOE

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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 A B C
MRF Y10
MRF Y11
MRF Y12
MRF Y13
MRF Y14
MRF Y15
MRF Y16C
MRF Y10: suitable for drilling the following rails 100 ARA-B, 115 and 119 LB RE
MRF Y11: suitable for drilling the following rails 100 ARA-B, 105 DL&W
MRF Y12: suitable for drilling the following rails 115, 119, 132, 136, 140 LB RE, 130 and 155 PS
MRF Y13: suitable for drilling the following rails 80, 90 LB ASCE and 100 ARA-A
MRF Y14: suitable for drilling the 85 LB ASCE rail
MRF Y15: suitable for drilling the 130 LB RE and 136 LE.VAL rails
MRF Y: universal positioning gauge for all rail sizes
•Note: other positioning gauge sizes available upon request.
HOLES DISTANCES
A
C
R
B
2 21/32" 7 1/4" 5 1/2"
3 1/2" 6" 6"
2 21/32" 7 1/4" 5 1/2"
3 1/2" 4 3/4" 4 3/4"
2 23/32" 6" 7"
3 1/2" 6" 6"
3" 6" -
2 7/16" 5" -
2 7/16" 7" -
2 3/8" 7" -
2 3/4" 6 3/4" 6 3/4"
2 11/16" 5 1/2" 5 1/2"
3 1/2" 6" 6"
UG
ES
ng
j
oint
b
ar
e
en rail en
d
RA
IL
END

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Allthebroachcuttersallowautomaticcoolingby means of the SR5000 unit supplied with the drills.
3.7) BROACH CUTTERS
These cutters rapidly produce high quality, accurate holes
in a single pass.The automatic lubrocooling system reduc-
es friction and eliminates heat build up during the drilling
operation. Under standard conditions a broach cutter can
drill 40-50 holes, depending on the hardness of the rail.
15128
15130
15132
15234
TSC 1 1/8"
15138
TSC 1 1/4"
TSC 1 5/16"
15144
15146
TSC 1 1/2"
TSC 3/4"
01354
01355
01356
01357
01358
01359
01360
01361
01362
01363
01364
12218
3-12224
3-12226
3-12228
3-12230
3-12232
3-12236
BROACH
CUTTER
PILOT
BIT
HOLE
DIAMETER
(inches)
7/8"
15/16"
1"
1 1/16"
1 1/8"
1 3/16"
1 1/4"
1 5/16"
1 3/8"
1 7/16"
1 1/2"
3/4"
7/8"
15/16“
1“
1 1/16"
1 1/8"
1 3/16“
1 1/4"
1 5/16“
1 3/8"
1 7/16"
1 1/2"
9/16"
3/4"
13/16"
7/8"
15/16"
1"
1 1/8"
MAX.
DEPTH OF CUT
(inches)
Ref. PPC 2
Ref. PPL 2
3-10528
2 "
7/8 "
3 "

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with adapter
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 70-100 holes, depending on the hardness
of the rail.
For tools of other types, check the dimensional compatibility (particularly the size of the attachment and the length).
APED...
Diam.
3.9) "LR 2" LUBROCOOLER CONCENTRATE, 1 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.
3.10)"LR 3" ANTIFREEZE CONCENTRATE of 1 or 5 gallons added to the lu-
brocooling mixture with the right percentage will maintain the lubrocooling
mixture fluid in negative temperature consitions.
LR 3
LR 2
PE70
PE95 C
PE130
PE160
PE190
PE220
PE130L-AR
PE3/4”-L1-AR
PE7/8”-L1-AR
PE1”-L1-AR
PE1-1/8”-L1-AR
PE1-1/4”-L1-AR
SPIRAL
BIT ADAPTER
HOLE
DIAMETER
(inches)
9/32”
3/8”
1/2”
5/8”
3/4”
7/8”
1/2”
3/4”
7/8”
1”
1 1/8”
1 1/4”
SPACER
APED70
APED 3/8 Y
APED 130
APED135/165
without adapter
without adapter
APED 130
without adapter
without adapter
without adapter
without adapter
without adapter
included in the APED 70
included in the APED 3/8 Y
included in the APED 130
included in the APED
135/165
DPE
DPE
included in the APED 130
DPE
DPE
DPE
DPE
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
ADDITIONAL
ACCESSORIES
without adapter
Diam.