JEI DRILLING & CUTTING SOLUTIONS RAILBEAST RDE-36 User manual

UNIT 21 EMPIRE BUSINESS PARK, ENTERPRISE WAY
BURNLEY, LANCASHIRE, UK, BB12 6LT
TEL: [phone] EMAIL: [e-mail]
OPERATOR’S MANUAL
ELECTRIC RAIL DRILLING MACHINE
R
RA AI IL LB BE EA AS ST T R RD DE E- -3 36 6

Contents
1. GENERAL INFORMATION............................................................................................... 3
1.1. Application................................................................................................................. 3
1.2. Technical data............................................................................................................ 3
1.3. Equipment included ................................................................................................... 4
1.4. Dimensions................................................................................................................ 5
1.5. Design ....................................................................................................................... 5
2. SAFETY PRECAUTIONS.................................................................................................. 6
3. STARTUP AND OPERATION........................................................................................... 8
3.1. Installing and removing the annular cutter.................................................................. 8
3.2. Installing and removing the rail profile templates........................................................ 9
3.3. Installing and removing the hole center positioner.....................................................10
3.4. Clamping the machine onto the rail and unclamping.................................................11
3.5. Connecting and disconnecting the cooling system....................................................12
3.6. Drilling.......................................................................................................................13
3.7. Replacing the motor brushes ....................................................................................15
4. ACCESSORIES...............................................................................................................16
4.1. Pressure cooling system with adapter.......................................................................16
4.2. Rail profile templates.................................................................................................18
4.3. Hole center positioners .............................................................................................19
5. DECLARATION OF CONFORMITY.................................................................................20
6. WARRANTY CARD..........................................................................................................21

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1. GENERAL INFORMATION
1.1. Application
The RAILBEAST RDE-36 is a drilling machine designed to drill holes in rails of
UIC54, UIC60, P50, P65, S49, or any other standard. The machine can drill holes
with diameters of 36 mm (1.42″) by using annular cutters.
Ordered separately rail profile templates allow the machine to be clamped onto a
rail. Hole center positioners allow you to get the correct span between holes.
1.2. Technical data
Voltage
1~ 220–240 V, 50–60 Hz
1~ 110–120 V, 50–60 Hz
Power
1020 W
Tool holder
19 mm (3/4″) Weldon
Maximum drilling diameter
36 mm (1.42″)
Maximum drilling depth
30 mm (1.18″)
Stroke
40 mm (1.57″)
Rotational speed with no load
520 rpm
Rotational speed with load
350 rpm
Protection level
IP 20
Protection class
I
Noise level
More than 70 dB
Vibration level
1.55 m/s2(5.1 ft/s2)
Required ambient temperature
0–40°C (32–104°F)
Weight
14.5 kg (32 lbs)

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1.3. Equipment included
1
RAILBEAST RDE-36 drilling machine
1 unit
2
Plastic box
1 unit
3
Handle
3 units
4
Cooling system
1 unit
5
4 mm hex wrench with a handle
1 unit
6
5 mm hex wrench with a handle
1 unit
–
Operator’s Manual
1 unit
6
1
2
5
4
3

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1.4. Dimensions
1.5. Design
Pressing screw
MOTOR start
Carrying handle
POWER switch
Feed shaft
MOTOR stop
Arbor
558 mm (22″)
213 mm (8.4″)
361 mm (14.2″)

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2. SAFETY PRECAUTIONS
1. Before use read this Operator’s, Manual and complete a training in occupational
safety and health.
2. Use only in applications specified in this Operator’s Manual.
3. Make sure that the machine has all parts and they are genuine and not damaged.
4. Make sure that the specifications of the power source are the same as those
specified on the rating plate.
5. Do not carry the machine by the power cord and do not pull the cord. This can
cause damage and electric shock.
6. Transport and position the machine by using the carrying handle.
7. Keep untrained bystanders away from the machine.
8. Before each use, make sure the correct condition of the machine, power source,
power cord, plug, control panel, and tools.
9. Before each use, make sure that no part is cracked or loose. Make sure to main-
tain correct conditions that can have an effect on the operation of the machine.
10. Before starting, make sure that the rail profile templates installed agree with the
rail standard.
11. Use the correct coolant for the ambient temperature.
12. Keep the machine dry. Do not expose the machine to rain, snow, or frost.
13. Keep the work area well lit, clean, and free of obstacles.
14. Make sure that the tool is correctly attached. Remove wrenches from the work
area before you connect the machine to the power source.
15. Do not use tools that are dull or damaged.
16. Unplug the power cord before you install and remove tools. Use protective gloves
to install and remove tools.
17. Do not make holes whose diameter or depth differ from those specified in the
technical data.
18. Do not use near flammable materials or in explosive environments.
19. Use eye and ear protection and protective clothing. Do not use loose clothing.
20. Do not touch chips or moving parts. Do not let anything catch in moving parts.
21. After each use, remove chips and coolant from the machine and the tool. Do not
remove chips with bare hands.
22. Unplug the power cord before you do maintenance or install/remove parts.

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23. Repair only in a service center appointed by the seller.
24. If the machine falls, is wet, or has any damage, stop the work and immediately
send the machine to the service center for check and repair.
25. Do not leave the machine when it operates.
26. If you are not going to use the machine, remove the tool from the holder. Then,
remove the machine from the work area and keep it in a safe and dry place.
27. If you are not going to use the machine for an extended period, put anti-corrosion
material on the steel parts.

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3. STARTUP AND OPERATION
3.1. Installing and removing the annular cutter
With the motor stopped, turn the handles (1) to move out the arbor. Install the arbor
as described before. Use gloves to put the correct pilot pin into the annular cutter (2).
Use a dry cloth to clean the cutter. Put the cutter into the arbor (3) to align the flat
surfaces (4) with the screws (5). Use the 4 mm hex wrench to tighten the screws.
To remove the cutter, loosen the screws (5) with the 4 mm hex wrench.
3
5
4
1
2

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3.2. Installing and removing the rail profile templates
Select rail profile templates (not included) that agree with the rail standard. Put the
templates on the pins. Use the 6 mm hex wrench to tighten the screws.
To remove the templates, use the 6 mm hex wrench.

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3.3. Installing and removing the hole center positioner
Select a hole center positioner (not included) that agrees with the rail standard, and
loosen the levers (1). Put the positioner onto the rail (2) so that the positioner face
aligns with the rail face (3). Lock the levers in this position. Next, use the 6 mm hex
wrench to tighten the screws (4) so that the positioner clamps onto the rail (5).
To remove the positioner, loosen the screws (4)and levers (1).
2
4
5
1
Clamped
Unclamped
3

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3.4. Clamping the machine onto the rail and unclamping
Put the machine onto the rail (1). Make sure that the locating pin is in the first groove
of the hole center positioner (2) and the pressing screw is in the resisting socket (3).
Then, tighten the screw (4) to clamp the machine onto the rail.
To unclamp the machine, loosen the pressing screw.
1
4
2
3

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3.5. Connecting and disconnecting the cooling system
Make sure that the bar of the frame is between the pin and the fitting (1). Next, attach
the cooling system to the fitting (2), and then fill the bottle with a coolant. Do not use
only water as the coolant. But you can mix water and drilling oil. Before you drill,
press the lever (3) several times. Press and release the lever during work to supply
the coolant.
To disconnect, pull out the hose from the fitting.
2
3
1

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3.6. Drilling
Set the power switch to ‘I’. Then, press the green MOTOR button to start the motor.
Slowly turn the handles (1) to move out the cutter and start drilling.
When the annular cutter goes through the workpiece, the slug core is
pushed out with a large force.
1

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After you drill the first hole, turn the handles opposite to (1), to retract the cutter.
Unclamp the machine as described before. Next, clamp the machine onto the rail in
the next groove of the hole center positioner, and make a next hole.
Continue as described until all holes are made. After the work is finished, press
the red MOTOR button to turn off the motor. Then, set the power switch to ‘O’ to turn
off the power.

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3.7. Replacing the motor brushes
Every 100 work hours, check the condition of the brushes. To do this, unplug the
power cord and remove the motor cover (1). Next, remove the pressing plate (2), and
then remove the brush holder (3) and the brush (4). If the brush is shorter than 5 mm
(0.2″), replace the two brushes with new ones.
Install in reverse sequence. Then, let the motor operate with no load for
20 minutes.
1
2
3
4

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4. ACCESSORIES
4.1. Pressure cooling system with adapter
Capacity of 5 liters.
Part number:
PJM-0676-10-00-00-0

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Make sure that the bar of the frame is between the pin and the fitting (1). Connect the
cooling system with the adapter to the fitting (2, 3). Open the valve (4). Next, turn the
handle (5). Move the handle up-down several times to increase the pressure in the
bottle.
To remove, close the valve (4). Pull up the release valve (6) to release excess
pressure, and then pull out the adapter from the fitting.
6
3
2
4
5
1

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4.2. Rail profile templates
Other templates available on request.
UIC54 templates:
RAIL-TEMPUIC54
UIC60 templates:
RAIL-TEMPUIC60
P50 templates:
RAIL-TEMPP50
P65 templates:
TAIL-TEMPP65
S49 templates:
RAIL-TEMPS49

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4.3. Hole center positioners
Other positioners available on request.
UIC54 positioner:
RAIL-POSUIC54
UIC60 positioner:
RAIL-POSUIC60
P50 positioner:
RAIL-POSP50
P65 positioner:
RAIL-POSP65
S49 positioner:
RAIL-POSS49

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5. DECLARATION OF CONFORMITY
Declaration of Conformity
JEI DRILLING & CUTTING SOLUTIONS LTD
UNIT 21 EMPIRE BUSINESS
ENTERPRISE WAY
BURNLEY, LANCASHIRE, BB12 6LT
We declare with full responsibility that:
RAILBEAST RDE-36 ELECTRIC RAIL DRILLING MACHINE
is manufactured in accordance with the following standards:
•EN 60745-1
•EN 55014
•EN ISO 12100
and satisfies regulations of the guidelines: 2014/30/UE, 2014/35/UE, 2006/42/UE,
2011/65/UE, 2012/19/UE.
Person authorized to compile the technical file:
David McFadden, Unit 21 Empire Business Park,
Burnley
Burnley, 3 September 2019 ___________________________
David McFadden
Managing Director