Cembre LD-2EN User manual

1
ENGLISH
15 M 073 E
RAIL DRILL TYPE LD-2E
LD-2E-110
LD-4EF
Cerfied Environmental
Management System
Cerfied Occupaonal
Health & Safety
Management System
Cerfied Quality
Management System
OPERATION AND MAINTENANCE
MANUAL

2
LD-2EN
LD-2EN-110
LD-4EN
basic drills
DESCRIPTION OF THE DRILLS:
LD-2E
LD-2E-110
LD-4EF
basic drills complete
with DBG-F2 railweb
clamping device

3
ATTENTION
– Beforeusingtheraildrilling,carefullyreadtheinstructionscontainedinthismanual.
SAVETHESE INSTRUCTIONS: this manual contains important safety and operating
instructions for the drilling machine.
– The degree of protection of the drilling machine against moisture is classified
“ordinary" (EN 50144-1 Standard).
Do not expose the rail drilling to rain and moisture; possible infiltrations of water
inside the electric motor determines the risk of electric shocks.
Mobile electric devices used outdoor must be connected to the supply by inter-
posing a safety interrupter for breakdown current.
– DISCONNECT always the power supply when servicing the drill:
before removing the broach cutters, spiral bits, positioning templates etc.
– 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.
USER INFORMATION in accordance with “Directives 2002/95/EC and 2002/96/EC rgarding
the reduction 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 manufactu-
rer. 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 reduce harmful environmental effects and promote the reuse and recycling of
materials contained in the equipment.
Unlawful disposal of such equipment will be subject to the application of administrative san-
ctions provided by current legislation.
Following information applies
in member states of the
European Union:

4
Ø 7 ÷ 33 mm
310 rpm
110 / 120 V AC-DC
1800 W
14 kg
17 kg
Ø 7 ÷ 40 mm
250 - 280 rpm (**)
220 / 230 V -50 Hz
LD-2E LD-2E-110 LD-4EF
see
"APPENDIX C"
page 29
(*) with broach cutters on thicknesses up to 50 mm
with special spiral bits on thicknesses up to 45 mm
(**) Two speeds: 280 rpm with broach cutters and spiral bits diameter smaller than 28 mm;
250 rpm with broach cutters diameter between 28 to 40 mm inclusive.
see
"APPENDIX B"
page 28
Drilling capacity (*):
Speed without load:
Electric motor:
Supply:
Power rating:
Automatic switch:
Weight:
Weight with "DBG-F2":
Recommended
gear sump oil:
Air Noise:
(Directive 2006/42/EC
annexe 1, point 1.7.4.2
letter "u")
Vibrations:
(Directive 2006/42/EC
annexe 1, point 2.2.1.1)
1. GENERAL CHARACTERISTICS
Ø 7 ÷ 33 mm
310 rpm
220 / 230 V - 50 Hz
Single phase, double insulation
protection against overheating caused by a current overload
and against unintentional start up following a drop in voltage, by
means of an automatic switch equipped with thermal cut-out
and underpower relay.
MOBIL DTE OIL LIGHT or ESSO TERESSO 32
or equivalent

5
2. ACCESSORIES SUPPLIED WITH THE DRILL
2.1) Guide bits for controlling the coolant system:
for broach cutters suitable for drilling thicknesses of up to 25 mm
– 1 pc PP 1, diameter 7 mm.
– 1 pc PP 2, diameter 8 mm.
for broach cutters suitable for drilling thicknesses of up to 50 mm
– 1 pc PPL 1, diameter 7 mm.
– 1 pc PPL 2, diameter 8 mm.
2.2) Spacer, type DPE, for controlling the coolant system, for special
spiral bits, diam. 7 ÷ 27,5 mm.
2.3) Adaptor, type ARE, for external coolant connection, to be used
with the SR5000 coolant unit.
2.4) Grub screw, M8x10
– 4 pcs for clamping cutters or bits on spindle shaft.
2.5) Socket head cap screws, M6x16
– 4 pcs for securing drilling jigs to front plate.
2.6) Socket head cap screws, M6x25
– 4 pcs for securing special drilling jigs 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 brush.
2.8) 140 ml oil bottle for gear sump.
Parts 2.1 to 2.8 are included in "ACCESSORIES KIT",
Code No 6001357.
2.9) Type SR5000 coolant unit.

6
3.1) DBG-F2 device (*) with moving arm for clamping the drill to
the rail web and track fittings, complete with the following end
pieces:
– TDB 1: for switch blades and compound frogs.
– TDB 3: for repairing (adjusting) existing holes on rails for subse-
quent application of electrical connections and for additional
special applications.
–TDB 6: standard end piece for rails and stock rails.
(*) Supplied with drilling machine ref. LD-2E, LD-2E-110 and LD-4EF.
3.2) “VAL LD” metal case for storing the drill complete with the DBG-F2 device, DBSN device
and VAL MPA tool case.
Also available VAL P24-CS plastic carrying case with folding handle and wheels.
3.2.1) “VAL LD-L”metal casefor storingthe drill completewith theDBG-LF2 device,DBSN device
and VAL MPA tool case.
3.1.2) DBSN device for clamping the drill
to flange rails, for use in conjunction with
the MPAF templates. Using this device the
raildrill canremainclamped inthe drilling
position even when trains pass over it.
3. ACCESSORIES TO BE ORDERED SEPARATELY
TDB 6
TDB 1 TDB 3
TDB 7
VAL P24-CS VAL LD-L
3.1.1) DBG-LF2 device with moving arm
complete with TDB 7 end piece for clamp-
ing the drill to girder rails and for additional
special applications.

7
3.4) 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 UIC 54 rail
– MPAF UIC60 on DRILLING AXIS of UIC 60 rail
•Note: Contact Cembre for selection of specific application
accessories.
3.5) MPAUuniversalpositioningtemplatesuitablebothforrepair-
ing existing holes on various fittings, and for drilling disused rails.
3.6) SPApositioningplatesfor drillingrailheads
with a centre-to-centre distance established
in the Railway boards standards, without the
need for marking out; for use in conjunction
with MPAF... positioning templates.
3.7) 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.
3.8) VAL MPA tool case suitable for storing
the accessories indicated in 3.5 - 3.8, and the
drilling tools.

8
3.9) Broach cutters
BROACH CUTTERS FOR RAILS IN STEEL QUALITY 700-900-1100 (UIC 860.0)
Broach cutter Guide bit
CY130
CY135
CY160
CY170
CY175
CY180
CY190
CY200
CY210
CY220
CY230
CY240
CY250
CY260
CY270
CY275
CY280
CY290
CY300
CY310
CY320
CY330
Ø
mm
13
13,5
14
16
17
17,5
18
19
20
21
22
23
24
25
26
27
27,5
28
29
30
31
32
33
CY140L
CY160L
CY170L
CY180L
CY190L
CY200L
CY210L
CY220L
CY230L
CY240L
CY250L
CY260L
CY270L
CY280L
CY290L
CY300L
CY320L
CY330L
MAX DRILLING THICKNESS
25 mm
LONG RANGE (L max = 88mm)
Broach cutter Guide bit
SHORT RANGE
Ref. PPL 1
Ref. PPL 2
Ref. PP 2
MAX DRILLING THICKNESS
50 mm
Ref. PP 1
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.

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7
7,1
8
8,5
9
9,5
10
11
12
13
13,5
FIG. 1
FIG. 2
SPECIAL SPIRAL BITS FOR RAILS IN STEEL QUALITY 700 - 900 - 1100 (UIC 860.0)
The drilling tools indicated in the tables guarantee optimum results. For tools of other types, check the di-
mensional compatibility (particularly the size of the attachment and the length).
3.11) LR2 BIODEGRADABLE LUBROCOOLANT
3 litre container to be used in a 5-10 % solution, for optimum operation of both broach cutters
and spiral bits.
3.12 LR3 ANTIFREEZE CONCENTRATE
3 litre added to the lubrocoolant mixture in the right concentration will
maintain the lubrocoolant mixture fluid in negative temperature conditions.
3l
– The special spiral bits in the PE range allow automatic cooling by means of the SR5000 unit supplied with the
drilling machine.
– All spiral bits in the PE range allow drilling of thicknesses up to 45 mm.
L max
ø
APED...
APE...
ø
L max
h
3.10) Spiral bits
PE 140
PE 160
PE 170AR
PE 175
PE 180
PE 190AR
PE 210AR
PE 220
PE 240AR
PE 275AR
Ø
mm
14
16
17
17,5
18
19
21
22
24
27,5
Adaptor
type
Figure
h
mm
L
max
mm
APED 135/165
Spiral Bit
type
(*)
PE 70
PE 71
PE 80
PE 85
PE 90
PE 95
PE 100
PE 110
PE 120
PE 130AR
PE 135AR
Ø
mm
Adaptor
type
h
mm
L
max
mm
APE 90
APE 95
APE 100
APE 110
APE 120
APED 130
Figure
1
1
2
(*) PE... AR: special high quality spiral bit.
Spiral Bit
type
(*)
1,6
76
76 1,6
APED 701,2
88
85
APED 80
APED 135/165
88
ONLY FOR LD-4EF
72
76
1,4

10
02
03 35 17
01
Detail of the
max pressure valve
FIG. 3 – COOLANT UNIT
The type SR5000 coolant unit consists of a tank complete with tube and maximum pressure valve
(01), 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, from the position of 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.
01 – Tank complete with hose
and max. pressure valve
02 – Tap
03 – Quick-coupling
17 – Vent valve
35 – Attachment valve
4. COOLANT UNIT TYPE SR5000 (Ref. to Fig. 3)

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36
35
03
FIG. 4
ARE adaptor
4.1) 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.
FIG. 5 – ARE ADAPTOR
•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.
– Using the 4 mm allen key provided with the drill, remove the appropriate coolant valve from its
seat and fit into the vent valve seat.
– Fit the vent valve into the removed coolant valve seat.
•When temperatures fall below 0° C the lubrocoolant
may freeze which could cause damage to the seals
contained in the drill coolant system.
It is therefore advisable, when storing the
drilling machine, to empty the lubrocoolant
system completely.
Proceed as follows (Fig. 4):
– Disconnect the quick coupling (03) 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.

12
FIG. 6
The spindle is advanced by moving the lever
(36) (see Fig. 6a). The lever is fitted with a release
pawl (39) which, when pressed, renders it inde-
pendent 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).
6c - With the hub released, moving the lever
towards the operator produces a corre-
sponding advance of this spindle.
6a - Moving the lever (36) towards the operator
produces a corresponding advance of the
spindle.
FIG. 7
5.1) 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).
SELF-LOCKING NUT
6b - With the release pawl (39) pressed, the lever is
released from its hub and can repeat the pre-
vious travel without the spindle moving.
5. SPINDLE ADVANCE LEVER (Ref. to Fig. 6)

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DISCONNECT always the power supply when servicing the drill:
before removing the broach cutters, spiral bits, positioning templates etc.
6.1) Assembling broach cutters (Ref. to Figs. 8-11).
6.1.1) Insert the guide bit in the cutter from the side of the spigot.
6.1.2) Using the lever (36), position the spindle shaft (07) so that both grub screws (18) 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 (71) (see Fig. 11).
6.1.3) Insert the cutter in the spindle shaft so that the two engaging dogs on the cutter spigot
line up with the grub screws.
6.1.4) Clamp the cutter by fully tightening the grub screws by means of the 4 mm male hexagon
key.
6.1.5) Check that the guide bit slides freely by applying slight pressure on it.
6.2) Assembling spiral bits (Ref. to Figs. 9 - 11)
6.2.1) 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. 11).
Short type broach cutter
Maximum drilling thickness: 25 mm
Guide bit PP..
Long type broach cutter
Maximum drilling thickness: 50 mm
Guide bit PPL..
Engaging dogs
07
18
FIG. 8 – ASSEMBLING BROACH CUTTERS
6. PREPARING THE RAIL DRILL

14
FIG. 10 – ASSEMBLING THE
BIT-SPACER UNIT
FIG. 9 – ASSEMBLING SPIRAL BITS
FIG. 11 – MANUAL SPINDLE
ROTATION
07
18
DPE *
DPE
Bits PE ... (e.g. PE70)
Bits PE ... (e.g. PE 220)
APE ...
* use only for APE, not required for APED
71
33
6.2.2) Insert into the spindle shaft, the DPE spacer required to activate the coolant system.
If it is necessary to use an APE... adaptor the bit must first be fitted in the corresponding
APE adaptor and locked with the appropriate grub screw, then the DPE spacer inserted.
Note: Adaptors type APED… (e.g. APED 135/165) do not require use of DPE spacer.
6.2.3) 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 againt the inner
seat of the spindle: this will enable the DPE spacer to open the coolant circuit (see Fig. 10).
6.2.4) Clamp the bit by fully tightening the two grub screws (18) using the 4 mm male hexagon key.

15
7. RAIL DRILL TYPE LD-2E ; LD-2E-110 ; LD-4EF
Code n. LD-2E ; LD-2E-110 ; LD-4EF each cover a basic drill (see page 1) complete with the
moving arm device DBG-F2 for clamping to the rail web and the track fittings (Ref. to Fig. 12).
The DBG-F2 clamping device consists of:
– Clamping unit
– Type TDB 1 end piece
– Type TDB 3 end piece
– Type TDB 6 standard end piece
– Socket head cap screws M 8x25 (2 pcs)
– Spring washers (4 pcs)
– Reference pin
FIG. 12 – DRILL WITH DBG-F2 DEVICE
reference
pin TDB 3
TDB 1
TDB 6
M 8x25 screws
and spring washers

16
TDB 3 end piece
for enlarging existing holes
on rails inherent in the application
of electrical connections and for
additional special applications.
TDB 1 end piece for switch blades
and composite frogs TDB 6 end piece for rails and stock rails
Seats to be used for
special applications.
FIG.13 – ASSEMBLY END PIECES
positioning pawl
pointing downwards
holding
plate
7.1) Assembling end pieces
TDB 1,TDB 6 and TDB 3 end pieces 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 is
shown in Fig. 13.
• When assembling the TDB 3 end piece ensure that the positioning pawl is pointing down-
ward in relation to the bolt.
• When disassembling the TDB 6 end piece ensure that, after removing the pivot, the com-
plete assembly is slid away downwards without acting on the holding plate.
• Over-advancing the spindle after drilling must be avoided when using theTDB 1 and TDB3
end pieces.

17
screws M6x16
reference
pin
MPAF...
MPAU
FIG. 14 – ASSEMBLY OF THE
TYPE “DBG-F2” CLAMP
Drilling machine
front plate
DBG-F2 Clamp
30
7.2) Assembly of the DBG-F2 clamping device on the drill
The DBG-F2 clamping device is fitted to the front plate of the drill, centred by means of the refer-
ence pin supplied and secured with the two socket head cap screws M8x25 (30) also supplied.
The assembly is illustrated in Fig. 14.
7.3) Assembly positioning templates (Ref. to Fig. 15)
NOTE: Only Cembre positioning templates and jigs are to be used with the rail drill.
7.3.1) The type MPAF.. and MPAU positioning templates are secured to the front plate (04) of
the drill by means of the two socket head cap screws M 6x16 supplied.
FIG. 15 – ASSEMBLY OF TEMPLATES

18
17
7.4) Clamping to the rail web (Ref. to Fig. 16)
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:
7.4.1) Withdraw the spindle shaft (07) completely by means of the lever (36).
7.4.2) Insert the threaded bush (39) of screw (11) into its seat (A) in the mobile arm (17) (see
detail in Fig. 17); use the hand-wheel (12) to completely open the mobile arm.
7.4.3) Place the drill on the track at the point to be drilled and clamp it by tightening the hand-
wheel fully down (12): the positioning template will automatically position the cutter or drill bit
in line with the designated axis; if precise positioning is necessary to the longitudinal track axis,
use the reference pin (01).
7.4.4) For rapid drill release, simply back-off the hand-wheel (12) by approximately two com-
plete turns, and while supporting the drill by its grip (09), pull the hand-wheel towards you. The
threaded bush (39) will disengage the seat (A) in the mobile arm (17) which will open automati-
cally, freeing the drill.
In this way, the operator can rapidly remove the machine from the track in case of danger, or
move on to drill another hole.
Thus, the next track engagement operation will be considerably simplified:
after positioning the drill at the point to be drilled, simply push the hand-wheel forwards so that
the threaded bush engages the seat (A) of the mobile arm. Now, a few turns on the hand-wheel
will be sufficient to engage the drill correctly on the track.
FIG. 16 – POSITIONING THE DRILL
(eg on UIC60 rail with MPAF UIC60 template)
39
11 17
A
17
39
11
12
36
17
0701
09

19
<>
N.B.: make sure the mains voltage corresponds to that on the drill rating plate.
N.B.: switch on the cooling system before starting the drill (§ 4).
8.1) 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 (§ 6.1), clamping
end piece (§ 7.1), positioning template (§ 7.3), the drill being clamped to the rail (§ 7.4), as follows:
8.1.1) Connect the female quick-coupling of the SR5000 coolant unit to the male coupling (12)
on the drill.
8.1.2) Open the tap (02) fitted onn the coolant unit hose.
8.1.3) Using the lever (36) bring the guide bit almost in contact with the rail (Fig. 17a); keeping
the release pawl (39) pressed, release the lever from its cup and return it to the initial position
(Fig. 17b), which will enable the travel of the lever (36) to be used in the most advantageous way.
8.1.4) Connect the electric plug and press the automatic switch (position "I") (Fig. 17d)
Fig. 17a Fig. 17b Fig. 17c
36
39
<>
<>
CAUTION: the automatic switch is equipped with
protection against motor overheating and with an under-
power relay; should the motor overheat or there is a fall
in voltage below the relay cut-out setting, the switch will
move into the "0" position. At this stage, if the conditions
are correct, the switch will have to be re-set manually.
FIG. 17d
AUTOMATIC SWITCH
8. DRILLING (Ref. to Figs. 17-18)

20
8.1.5) ONLY FOR LD-4EF DRILL
Set the motor speed, by means of the selector
switch under the automatic switch (see Fig.
17e), in correlation to the diameter of the hole
to be. We suggest to use the standard speed
(280 rpm) for holes smaller than ø 28 mm and
the lower speed (250 rpm) for holes between
dia 28 and 40 mm inclusive.
8.1.6) 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.
8.1.7) The guide bit will enable the lubrocoolant to be discharged throughout the drilling
process.
8.1.8) When drilling has been completed, fully retract the spindle, stop the motor by pressing
the automatic switch (position " 0 "), and make sure that drilling swarf is removed before
recommencing drilling.
8.1.9) After drilling it is advisable to remove all swarf from the tool and spindle area.
8.2) Drill fitted with“long”type broach cutter (for drilling thicknesses
of up to 50 mm).
Follow the sequence described in § 8.1, taking care to position
the drill on the rail by keeping the spindle fully withdrawn.
36
35
02
39
ONLY FOR LD-4EF DRILL:
switch for changing of the spindle speed
FIG. 17e
SPEED CHANGE SWITCH
FIG. 18 – DRILLING