ar 60d - deltaline...hand held hydraulic installation kit for setting the cembre bonding bush ( ar...

2

Electrical Permanent Contact for rail web type AR 60D for hole diameter 3/4”

bcd

a

Railweb thickness: between 17/32" to 11/16".This system has been studied, projected and realized by Cembre in 1988 after a deep analysis of existing electrical connection systems and their performances. The aim of the Cembre system is to provide a general and substancial improvement on the most important ca-ractheristics of a contact between the rail and the electric cables like:– extremely low resistance (in terms of micro-ohms);– easy installation procedures and not depending on operator skilness;– short installation time (less than one minute for each operation);– possibility of disconnection / connection of attached cables.– cold extruded (requires no heating to the rail).

System componentsare as follows:

To be installed by: Hydraulic tool type HTEPE-DETY or tool type RHTEP

a – Electrolytically tin-plated copper bush type AR 60-1

b – Steel M12 screw with hollow hex head (1 piece)

c – Flat steel washerd – Self-locking nut

After extensive tests, either in laboratory or in the field, the system has been recognized as totally reliable and per-fectly matching the above listed requirements.

RAIL WEB ELECTRICAL CONNECTION SYSTEM FOR RETURN TRACTION AND GROUNDING APPLICATIONS

PATENTED • PATE

NTE

D •

AR 6

0DAR 60D

Copper bush

Screw with (1 Piece) hollow hex head

Flat steel washer Self-

locking nut

Lug

3

AR 60D ASSEMBLY

Ø inch

AR 60D 17/32" ÷ 11/16" 3/4" CAL 19.20 OG 13.2

inch

! "

∅

OK NO

# $

% &HTEPE-DETY or RHTEP

' ( )

4

AR 6

9DRAIL WEB ELECTRICAL CONNECTION SYSTEM

FOR SIGNALLING DEVICES

PATENTED • PATE

NTE

D •

Copper bush

Steel M6screw with (1 Piece) hollow hex head

Flat steel washer

M6 Self-locking nut

Lug

Railweb thickness: between 17/32" to 11/16"

System components are as follows:a – Copper bush type AR 69D-1 protected on surface by suitable metal platingb – Steel M6 screw with hollow hex head c – Flat steel washerd – M6 self-locking nut

To be installed by: Hydraulic Tool type HTEPE-DETYor RHTEP (using installation kit type AR69-INST)or hand held ratchet tool Type MTE1

cd

a

b

Electrical Permanent Contact for rail web type AR 69D, for hole diameter 3/8"

AR 69D

5

AR 69D ASSEMBLY

Ø inch

AR 69D 17/32" ÷ 11/16" 3/8" CAL 95.10 OG 6.5 M9M5

inch

! "

∅

$#

% &HTEPE-DETY , RHTEPor MTE1

' ( )

OK NO

6

AR 260DAR 280*

RAIL WEB CABLE CONNECTION SYSTEM DOUBLE CONTACT BUSH TYPE

Electrolyticallytin-plated copper bush

Stainless steel Bolt

Stainless steelflat washers

Stainless steel self-lock nut

Cable lugs

• Traction return bonding • Continuity bonding• Signal track circuit connection • Ground bonding

Electrolyticallytin platedcopper alloy washer

Installation Tool

CABLE CONNECTION ASSEMBLY

Systemcomponentsare asfollows:

AR 260Da – Electrolytically tin-plated copper bush type AR 260-1b – Electrolytically tin-plated copper alloy washer type AR 260-2c – M12x70 flat steel boltd – M12 stainless steel flat washere – M12 stainless steel self-lock nut

To be installed by:hydraulic tool typeHTEPE-DETYor RHTEP for AR 260D(HTEPY for AR 280)

c

d

a

b

de

AR 280a – Electrolytically tin-plated copper bush type AR 280-1b – Electrolytically tin-plated copper alloy washer type AR 280-2c – M14x70 flat steel boltd – M14 stainless steel flat washere – M14 stainless steel self-lock nut

*AR 280 with

copper lug 2A48-M14

approved by

NEW YORK CITY

TRANSIT AUTHORITY

PATENTED • PATE

NTE

D •

RAIL WEB CABLE CONNECTION APPLICATIONS

AR 26

0D AR

280

7

AR 260D and AR 280 ASSEMBLY

Ø inch

AR 260D 17/32" ÷ 11/16" 3/4" CAL 19.20 OG 13.2

AR 280 9/16" ÷ 5/8" 1 1/8" CAL 118.1532 OG 15.2

inch

! "

∅

OK NO

$#

% &HTEPE-DETYor RHTEP for AR 260D(HTEPY for AR 280)

'

(

pp

)

8

Electrical Permanent Contact for rail web type AR 61E and AR61DE for hole diameter 7/8”

bc

a

System componentsare as follows:

To be installed by: Hydraulic tool type RHTEPE-12-E and BAS-19

a – Electrolytically tin-plated copper bush type AR 61E-1

b – M12 steel expansion boltc – locking washerd – M12 stainless steel self-lock nut

SINGLE SIDE BONDING SYSTEM FOR CONTINUITY AND EARTHING APPLICATIONS

PATENTED • PATE

NTE

D •

AR 61

E AR6

1DE AR 61E

AR 61DE

TERMINAL LUG

d

RHTEPE-12-E

BAS-19

Railweb thickness: between 0.31" to 0.87".This unique system was developed by Cembre in respon-se to a requirement for a version of the rail web bonding system, which could be installed in situations where ac-cess is limited to one side of a rail or trackside structure.

Examples include; • Running rail with check rail in situ • Switches and crossings • Circular hollow section stanchions • Blind holes in thick rail web

The Single Side Bonding System has been designed around the same basic principles as Cembre’s existing systems:• Low electrical resistance due to intimate contact between bush and hole surfaces • Simple installation method that does not depend on operator skill • Quick and easy to install (2 minutes for complete installation and assembly) • Easy to connect/disconnect cables for fault finding/maintenance • Does not rely on tight hole tolerances • ‘Extrusion’ installation method provides a seal between the bush and the hole preventing moisture ingress and corrosion, increasing the longevity of the connection

Electrical and mechanical testing has been carried out on the system including: • Temperature cycling • High current loading • Salt chamber corrosion testing • Mechanical flexion testing

9

AR 61E and AR61DE ASSEMBLY

! "

OK NO

#

% &

' *

Ø inch

AR 61E 0.49" ÷ 0.87"7/8" CAL 22.23 OG 13.2 FASTENER

ASSEMBLY

RHTEPE-12-EBUSH

INSTALLATIONTOOL

BAS-19FASTENER

INSTALLATIONTOOLAR 61DE 0.31" ÷ 0.49"

inch

ø 7/

8”

Check hole diameter using CAL 22.23

Assemble the bush and OG13.2 plunger to RHTEPE-12-E bush installation tool

BUSH RHTEPE-12-ECAL 22.23 OG 13.2 Insert bush into hole and operate tool to install bush

INSTALLED BUSH

$

Assemble terminal lug, locking washer, expan-sion bolt and M12 NUT against bush flange. Se-cure BAS-19 to threaded end of expansion bolt.

TERMINAL LUG LOCKING WASHER

M12 NUTEXPANSION BOLT

BAS-19

Tighten BAS-19 to push thrust pin through expan-sion bolt.

BAS-19

T [Nm]

80 50M12

Cu AlD

T

10

RAIL WEB ELECTRICAL CONNECTION SYSTEM TYP AR

The advantages of using the Cembre rail web contacts are that the bush can be installed in all weather and environmental conditions, with a simple, easy to operate portable tool, producing a consistent, quality installation, independent from the skill of the operator. The reduced installation time of this system results in overall cost savings.During installation the bush is ‘extruded’ and the copper material flows into the wall of the hole, compensating for variation in hole size and filling any voids and uneven surfaces.

Extensive testing, performed in the test laboratory and in the field, have demonstrated a low and constant resistance, mecha-nical stability and protection from atmospheric corrosion.

Examples of the electrical tests

Heat Cycling Tests Short Circuit Testing On site testing

Salt Mist Exposure Testing

!

" #

Schematic view of the ex-trusion process (section)

Examples of tests in salt water environments

11

TYPICAL APPLICATIONS

Examples of lines equipped with automatic block.

Examples of AR60Dsystem in electricjoint applications.

Features, and advantages of this systemare explained in various railways magazines

Transmission of coded and return current on lines fitted with automatic block

Signalling and traction current connection to manganese steel cast exchange units

Various connections involved in the train loca-tion system

Return current connections to substations Connections of metallic structures to rails for grounding purpose

Electrical connection of underground metal structures to rails

The AR60D system is used world wide proving to be fully reliable in all the working conditions.

AR60D installation

Protection equipment

12

ELECTRICAL CONNECTION SYSTEMS TO RAILSAND TO TRACK EQUIPMENT

1) Example of electrical connections using a low stranded con-ductor to provide electrical continuity on cast manganese ste-el crossovers.

1a) AR60D rail web connection, rail side2) Example of electrical connections using a flexible cable to pro-

vide electrical continuity on cast manganese steel crossovers.2a) AR60D rail web connection, rail side3) AR260D double contact rail web connection

1

1a

2

2a 3

13

HYDRAULIC SYSTEMS FOR RAIL WEB ELECTRICAL CONNECTIONS AR…., TYPE

HTEPE-DETYHand held hydraulic installation kit for setting the Cembre bonding bush (AR 60D and AR 260D) into the rail web consisting of the following accessories: HTP-Z hand pump, RHTEPE-S extruding head, VAL-P14 plastic carrying case, CAL 19.20 gauge and 2 OG 13.2 plungers. The HTP-Z hand pump has a 3 feet flexible hose and can be connected to hydraulic heads as RHTEP, TC025, RH50, RHTD1724

RHTEPSystem consisting of:a - Hydraulic head type RHTEP-S to be connected to a pump deve-

loping a nominal pressure of 10,000 psi, for example B70M-P24A battery operated hydraulic pump (see page 74-77)

b - 2 plungers type OG 13.2 in special steel (for extruding AR60 bonds)

c - CAL 19.20 gauge for both check of the rail hole and for screwing of the plunger itself into the head (for AR60 bonds)

d - metal case type VAL RHTEP

KIT AR 69-INSTIncluding:– CAL 95.10 Gauge– M9 M5 Adapter – OG 6.5 PlungerFor the installation of the electrical contact AR 69D type

ECR19+ECR1 KitsIn order to remove AR60D bushes from the rail, available (upon re-quest) is the ECR 19 kit (punch + puller) with the positioner ECR-1.For use please refer to the fol-lowing picture

Dimensions:Pump body: length 10.8 in.

width 5.12 in.Head: length 4.5 in.Total weight: 7.7 lbs

Dimensions:length: 4.17 in.Weight: 2.42 lbs

EXTRACTOR TO REMOVE AR 60-1 BUSHES FROM THE RAILS

MTE-1The MTE1 hand setting tool provides an easy and quick mechani-cal installation. The tool comes complete with:- 2 plungers 0G 6.5 type in special Steel (for extruding AR69D

bonds)- CAL 95.10 gauge for both check of the rail hole and for

screwing of the plunger itself into the head- Canvas bag - Weight: 3 lbs

MECHANICAL HAND SETTING TOOL FOR AR69D

14

Typical installation of Cembre Temporail

TEMPORARY RAIL ELECTRICAL CONNECTION SYSTEM TEMPORAILFOR RETURN CURRENT, SIGNALLING AND EARTHING APPLICATIONS

TEMPORAILThe Temporail system of connections and tooling provides a quick and reliable means to guarantee continuity of conductivity in rails during maintenance, repair and new installations. Essential for maintaining return current connections, the Tempo-rail system is also ideal for temporary signaling applications and earthing between the line and adjacent trackside structures.

Cembre Temporail system brings to all rail types with 4.9, 5.5 or 5.9 inc. foot• Easy installation /removal using Cembre patented tool HT-TRC• Safer working without the risks associated with alternative sys-

tems• Connection without any drilling or welding • No grinding or cleaning from previous operations• High vibration resistance• Accurate location on rail foot• Reusability due to controlled use of force

Temporail kit code Comprising

RTC1Al10-2000*

Two Steel contact clamps interconnected by

6.5 ft. 250 MCM insulated Aluminum flexible conductor cl.5 terminated both ends with Aluminium lugs and fixed with M10 Steel bolts and plain washers.

*Please refer to Cembre to verify the suitability of your rail profile with this clamp

HT-TRC hydraulic tool• Specifically designed to insert and extract Cembre Temporail

clamp • Works on all rail types with foot up to 5.9 inc.• Patented tool with safety feature protects against

ejection of metal pieces during extraction

Temporail requires no preliminary prepara-tion to ensure good electrical connection

as the clamp deeply scores the surface of the rail foot during installation.

Simple, safe insertion and extraction of Cembre Temporail

Insertion

Extraction

PATENTED • PATE

NTE

D •

New

15

RAIL DRILLS

LD-1PY-ECO - 2 cycle gasGENERAL FEATURES:• Engine: 2 cycles• Displacement: 45.4 cc• Fuel: 2% (1:50) oil/gasoline mixture • Start: by rope pull• Clutch: Centrifugal with automatic intervention• Power: 1.9 HP; 1.4 kW / 7500 rpm• Drilling range: Ø 9/32" to 1 9/16"• Max drilling thickness: 2 3/4”• Weight: 41.5 lbs

LD-2EY - ElectricGENERAL FEATURES:• Electric single phase engine: - supply voltage 120 V - 60 Hz - power rating 1.8 W• Drilling range: Ø 9/32” to 1 1/2” • Max drilling thickness: 2 3/4” • Weight: 38 lbs

Cembre Rail Drilling Machines have been specifically designed for use in Railway applications to provide a consistent and accurate hole, in all types of weather conditions.Due to their compact size, our drill can save considerable time by allowing direct operation in cases which would normally require the removal of armament.Special twist drill bits can be used for hole diameters of 9/32 to 1 1/8” on rail up to 3 1/2” thick. Broach cutters can be used for hole diameters 3/4” to 1 1/2” on rails up to 2 3/4” thick.The drills are provided with a coolant system consisting of a reservoir and pump for use with suitable cooling lubricants. Connection to the rail drill is by a quick coupler. The units are lightweight and designed for single operator use.

PATENTED • PATE

NTE

D •

PATENTED • PATE

NTE

D •

According to phase 2European Directives

16

LD-41PY - Four cycle gasGENERAL FEATURES:• Engine: four cycle• Displacement: 35.8 cc• Fuel: unloaded regular grade gasoline• Start: by rope pull• Clutch: centrifugal with automatic intervention• Power: 1.3 HP ; 1 kW• Weight: 43 lbs

Drilling range: Ø 9/32” to 1 1/2”

LD-12BY - BatteryGENERAL FEATURES:• Direct current electric motor• Supply voltage: 24 V DC• Power rating: 345 W• Weight: 37 lbs

Drilling range: Ø 9/32” to 3/4”

BATTERY PACK:– BP 24-16 (24 V DC 16 Ah): 33.2 lbs.– BP 24-10 (24 V DC 10 Ah): 24.2 lbs.• Battery condition display• Protection fuse• Battery charger 24V 2A max.

BATTERY PACK24 V DC 16 Ah

BATTERY PACK24 V DC 10 Ah

RAIL DRILLS

PATENTED • PATE

NTE

D •

PATENTED • PATE

NTE

D •

PATENTED • PATE

NTE

D •

LD-8H - HydraulicGENERAL FEATURES:• Engine: hydraulic• Oil input flow: 5 gpm• Oil input pressure: 2,000 psi• Power: 2 kW• Weight: 44 lbs

Drilling range: Ø 9/32” to 1 1/2”

According to phase 2European Directives and

EPA regulations

17

RAIL DRILLS

To the Railweb

This system is ideally suited to working when the track is under possession or if not under posses-sion when adequate train sighting provision is in place, however removal from the rail can be quickly achieved if so required. Using this arrangement, a hole can be drilled in correspondence of tie.

LD-1PYGR-ECOGENERAL FEATURES:• Engine: 2 cycles• Displacement: 45.4 cc• Fuel: 2% (1:50) oil/gasoline mixture • Start: by rope pull• Clutch: Centrifugal with automatic intervention• Power: 1.9 HP; 1.4 kW / 7500 rpm• Drilling range: Ø 9/32" to 1 9/16"• Max drilling thickness: 2 3/4”• Weight: 41.5 lbs.

LD-2EYGRGENERAL FEATURES:• Electric single phase engine: - supply voltage 120 V - 60 Hz - power rating 1.8 kW• Drilling range: Ø 9/32” to 1 1/2” • Max drilling thickness: 2 3/4” • Weight: 38 lbs

LD-41PYGRGENERAL FEATURES:• Engine: four cycle• Displacement: 35.8 cc• Fuel: unloaded regular grade gasoline• Start: by rope rull• Clutch: centrifugal with automatic intervention• Power: 1.3 HP ; 1 kW• Drilling range: Ø 9/32” to 1 1/2”• Weight: 43 lbs

Typical fixing situations:

Rail drills for drilling in correspondence of guard rail

18

STANDARD ACCESSORIES (ALWAYS SUPPLIED WITH THE DRILLING MACHINE) RAIL DRILLS TYPE LD-1PY-ECO AND LD-2EY

DBG-Y Over Rail ClampFor clamping of drilling machine to rail web and track fittingsComplete with• TDB 6 termination

ARE Adaptor For the external application of the coolant. Fits directly to the SR 5000 coolant unit coupler

Oil for the gear box for LD-3PY 100 ml (6001361)

Measure for mixture preparation* (6261300)It allows to prepare the oil-gas mixture

SR 5000 Coolant unitCoolant unit consisting of pressure vessel and hose, fitted with a manual pump and maximum pressure valve. Connection to the drilling machine is by quick coupler.

Range of tools• 1 x spark plug key*• 1 x 5 mm Allen key (6134020)• 1 x 6 mm Allen key (6134030)• 1 x 4 mm Allen key, with handle (6134010)• 1 x swarf brush (6261310)

* Accessory supplied only for LD-1PY-ECO (6134040) and LD-41PY (6134042) rail drills

Guide Bits Allow the automatic control (opening and closing) of the flow of the cooling mixture during the drilling operation. They must be inserted in the rear of the cutter, before the cutter is located into the spindle.• PPC2 For use with short broach cutters (7/8” depth of cut) • PPL2 For use with long broach cutters (2” depth of cut)

DPE Spacer For use with APE adaptor to activate the coolant when using spiral drill bits.

Socket head cap screws 4 pcs for clamping cutter or adaptor into spindle shaft (6340160)4 pcs for securing drilling template to the front plate (6900316)4 pcs for securing heavy duty drilling template to the front plate (6900330)

Oil for the gear box for LD-2EY 140 ml (6001362)

*

*

These machines are supplied with the following accessories:

FOR USE WITH BROACH CUTTERS

FOR USE WITH SPIRAL BITS

19

OPTIONAL ACCESSORIES FOR RAIL DRILLING MACHINES (TO BE ORDERED SEPARATELY)

VAL LD-SR • Steel carrying case for RAIL DRILL and SR 5000

VAL LD • Steel carrying case for RAIL DRILL• Accommodates the complete drill together with the DBG-Y clamp and the VAL-MPA tool case• 23 1/2” (L) x 13 1/2” (W) x 18 1/2” (H)

VAL MPA • Suitable for storage of rail shoes, cutters and accessories• 15 1/2” (L) x 13 3/4” (W) x 2 1/4” (H)

DBG-LY device for clamping the drill to the girder rails

DBG-GR device for clamping the drill in correspondance of guard rail

DBG-AY device for clamping the drill to the third rails For drilling 150 lb and aluminium composite contact rails form one side(to be used with TST 50 two stage template).

LUBROCOOLER LR2 concentrate, 1 or 5 gallons. This product of vegetable origin, to be watered down in the percentage 95% water, 5% oil, will provide a white color mixture very effective for the drilling operations resulting in no heating at the rail or the drilling machines

ANTIFREEZE Concentrate of 1 or 5 gallons LR3 added to the lubro cooling mixture with the right percentage will maintain the lubrocooling mixture fluid in negative temperature conditions.

TST 50 two stage template (to be used with DBG - AY clamp)This device enables the drilling of 150 lb and aluminium composite contact rails from one side.TST 50 Restart of work stroke: 1.97”Typical application: – Aluminium composite rail – 150 lb contact rail (Please see pag. 20 for accessories)

OPTI-2 engine lubricantOne mix for all 2 cycle engines

VAL P24-CSVAL P24 with wheels and folding handle.

VAL P24 • Plastic carrying case for rail drills• Accommodates the complete drill together with the clamping device and accessories.• 30 (L) x 18 (W) x 19 (H)

20


Cembre Rail Shoes Drilling On Running Rails

MPAU Cembre universal rail shoe (for other types of rail or special application such as drilling #20 high speed switch points)MPAU-10 Cembre universal short rail shoe (for other types of rail or special application)MPAF 40 LB ASCE Cembre Shoe for drilling 40 LB ASCE rail (Bolt hole elevation 1 9/16”)MPAF 60 LB ASCE Cembre Shoe for drilling 60 LB ASCE rail (Bolt hole elevation 1 115/128”)MPAF 80 LB ASCE Cembre Shoe for drilling 80 LB ASCE rail (Bolt hole elevation 2 3/16”)MPAF 85 LB ASCE Cembre Shoe for drilling 85 LB ASCE rail (Bolt hole elevation 2 17/64”)MPAF 85 LB PRR Cembre Shoe for drilling 85 LB PRR rail (Bolt hole elevation 2 1/16”)MPAF 85 LB PS Cembre Shoe for drilling 85 LB PS rail (Bolt hole elevation 2 15/64”)MPAF 90 LB ARA-A Cembre Shoe for drilling 90 LB ARA-A rail (Bolt hole elevation 2 9/16”)MPAF 90 LB ASCE Cembre Shoe for drilling 90 LB ASCE rail (Bolt hole elevation 2 45/128”)MPAF 100 LB ARA-A Cembre Shoe for drilling 100 LB ARA-A rail (Bolt hole elevation 2 3/4”) MPAF 100 LB ARA-B Cembre Shoe for drilling 100 LB ARA-B rail (Bolt hole elevation 2 65/128”)MPAF 100 LB ASCE Cembre Shoe for drilling 100 LB ASCE rail (Bolt hole elevation 2 65/128”)MPAF 100 LB DY Cembre Shoe for drilling 100 LB DY rail (Bolt hole elevation 2 5/8”)MPAF 100 LB NH Cembre Shoe for drilling 100 LB NYNH& H rail (Bolt hole elevation 2 39/64”)MPAF 100 LB RE Cembre Shoe for drilling 100 LB RE rail (Bolt hole elevation 2 45/64”)MPAF 100 LB RE-HF Cembre Shoe for drilling 100 LB RE-HF rail (Bolt hole elevation 2 45/64”)MPAF 100 LB PRR Cembre Shoe for drilling 100 LB PRR rail (Bolt hole elevation 2 9/32”)

MPAF 100 LB PS Cembre Shoe for drilling 100 LB PS rail (Bolt hole elevation 2 31/64”)MPAF 105 LB DY Cembre Shoe for drilling 105 LB DY & 110 LB RE rail (Bolt hole elevation 2 43/64”)MPAF 115/119 LB RE Cembre Shoe for drilling 112/115/119 LB RE rail (Bolt hole elevation 2 7/8”)MPAF 122 CB Cembre Shoe for drilling 122 CB rail (Bolt hole elevation 2 7/8”)MPAF 127 LB DYM Cembre Shoe for drilling 127 LB DY rail (Bolt hole elevation 3 1/8”)MPAF 130 LB RE Cembre Shoe for drilling 130 LB RE/HF-A rail (Bolt hole elevation 2 3/4”)MPAF 130 LB RE-HF Cembre Shoe for drilling 130 LB RE/HF rail (Bolt hole elevation 3 1/16”)MPAF 130 LB RE-HFB Cembre Shoe for drilling 130 LB HF-B rail (Bolt hole elevation 3 3/8”)MPAF 130 LB PS Cembre Shoe for drilling 130 LB PS rail (Bolt hole elevation 2 3/4”)MPAF 131 LB RE Cembre Shoe for drilling 131 LB RE rail (Bolt hole elevation 3 1/2”)MPAF 132 LB RE Cembre Shoe for drilling 132 LB RE running rail (Bolt hole elevation 3 3/32”)MPAF 133 LB RE Cembre Shoe for drilling 133 LB RE rail (Bolt hole elevation 3”)MPAF 136 LB RE Cembre Shoe for drilling 136 LB RE rail (Bolt hole elevation 3 3/32”)MPAF 136 LB LVM Cembre Shoe for drilling 136 LB LE VAL rail (Bolt hole elevation 3 1/16”)MPAF 140 LB RE Cembre Shoe for drilling 140 LB RE and 140 PS rail (Bolt hole elevation 3”)MPAF 141 LB AB Cembre Shoe for drilling 141 LB AB and 141 LB RE rail (Bolt hole elevation 3 3/32”)MPAF 152 LB PS Cembre Shoe for drilling 152 LB PS rail (Bolt hole elevation 3 3/4”) to be used with PFA1 (arbour extension) and PPL5 (Pilot Bit)MPAF 155 LB PS Cembre Shoe for drilling 155 LB PS rail (Bolt hole elevation 3 3/8”) to be used with PFA1 (arbor extension) and PPL5 (Pilot Bit)

Rail shoes for positioning the drill on running and guard railsEnable the automatic positioning of the machine on the drilling axis of each specific rail.

SPA/2-HSB Suitable to adjust the drilling height to be used in combination with MPAU template.

21


Cembre Rail Shoes Drilling On Guard Rails (Using DBG-GR clamp)

MPAF 100 LB ARA-B GR Cembre Shoe for drilling 100 LB ARA-B guard rail (Bolt hole elevation 2 1/4”)MPAF 115/119 LB RE GR Cembre Shoe for drilling 112/115/119 LB RE guard rail (Bolt hole elevation 2 5/8”)MPAF 115 LB-RE-3132 Cembre Shoe for drilling 115 LB-RE-3132 guard rail (Bolt hole elevation 3 1/32”)MPAF 132 LB-RE-3932 Cembre Shoe for drilling 132 LB RE guard rail (Bolt hole elevation 3 9/32”)MPAF 136 LB-RE-314 Cembre Shoe for drilling 136 LB RE guard rail (Bolt hole elevation 3 1/4”)

Cembre Rail Shoes Drilling On Girder Rails (Using DBG-LY clamp and 2” depth cutters)

MPAF 128/149 LB GR Cembre Shoe for drilling girder rail (Bolt hole elevation 3”)MPAF 128/149 LB-GR/1 Cembre Shoe for drilling girder rail (Bolt hole elevation 2 3/4")MPAF 149 LB GR 234 Cembre Shoe for drilling girder rail (Bolt hole elevation 2 3/4”)MPAF GGR 118 Cembre Shoe for drilling girder rail (Bolt hole elevation 2 3/8”)MPAF RI 60 N Cembre Shoe for drilling girder rail (Bolt hole elevation 2 7/8”) MPAF R160-87 Cembre Shoe for drilling girder rail

MPAF NP4AM Cembre Shoe for drilling girder rail (Bolt hole elevation 2 7/8”)MPAF BA9101 Cembre Shoe for drilling 180-105 LB girder rail (Bolt hole elevation 2 7/8”) MPAF TR68 Cembre Shoe for drilling girder rail (Bolt hole elevation 3 3/32")

Picture A

VERTICAL POSITIONING TEMPLATE

Cembre Rail Shoes Drilling On Aluminum Composite Rails (using DBG-LY and 2" depth spiral bits)

MPAF-ASC7L Cembre Shoe for drilling ASC7L rail (Bolt hole elevation 1 47/64")

Cembre Rail Shoes Drilling On Check Rail Type UIC33 (using DBG-UIC33, UIC33 Spacer)

MPAF-UIC33 Cembre Shoe for drilling UIC33 rail (Bolt hole elevation 1 3/8" from the top of the rail)

Cembre Rail Shoes Drilling On Crane Rails (using DBG-AY and 2” depth cutter with PPL2)

MPAF-175LB-258 Cembre Shoe for drilling 175 LB rail (Bolt hole elevation 2 5/8)MPAF-171LB-258 Cembre Shoe for drilling 171 LB rail (Bolt hole elevation 2 5/8)MPAF-104LB-2716 Cembre Shoe for drilling 104 LB rail (Bolt hole elevation 2 7/16)MPAF-105LB-21364 Cembre Shoe for drilling 105 LB rail (Bolt hole elevation 2 13/64)MPAF-135LB-21532 Cembre Shoe for drilling 135 LB rail (Bolt hole elevation 2 15/32)

MPAS RI 60 N Cembre Shoe for drilling vertically in the groove of girder rail type RI60N (see picture A)

MPAS 35G-GP Cembre Shoe for drilling vertically in the groove of girder rails type 35G and 35GP (see picture A)

22

MRF SR-SFA POSITIONING JIG

MRF SR-SFA positioning jigs and accessories facilitate accurate drilling in rail of holes with predefined centres namely using Cembre drilling machines:- 2 holes with centres of 145 mm (fig. 1, Pos. 1 and 2)- 2 holes with centres of 270 mm (fig. 1, Pos. 1 and 3)- 3 holes with centres of 148 mm (fig. 1, Pos. 4, 5 and 6)

23

MRF SR-SFA POSITIONING JIG

Assembly:

a) Select the SR…. template kit according to the rail to be drilled.

b) Assemble the SR templates on to the SR-SKI support, fixing with the M6x16 screws supplied (ref. fig. 3 and 4); locating pins on the support will ensure correct positioning.

c) Assemble the support on to the the front plate of the drilling machine, centre it by the pins and tighten it by the 2 screws M6x25 supplied with the drilling machine (ref. fig. 5).

d) Position the jig in the required place on the rail head and lock it by the handle clamps (ref. fig. 6).

e) When locking the jig align, if necessary, the appropriate cen-tre line on the jig with a reference mark on the rail head (ref. fig.7). Should it be necessary during the drilling phase to move the jig, exact repositioning can be achieved via the reference mark on the rail head.

SHOES AND TERMINATION BLOCKS FOR TIEFENBACH WHEEL SENSOR

Rail Shoe Termination Block

100 RE SRT100 RE TDB6/100RE100 ASCE SRT100 ASCE TDB6/100ASCE105 DY SRT105 DY TDB6/105DY112 RE SRT112 RE TDB6/112RE115 RE SRT115 RE-86.5 TDB6/115RE119 RE SRT119 RE TDB6/119RE127 DY SRT127 DY TDB6/127DY132 RE SRT132 RE-86,5 TDB6/132RE133 RE SRT133 RE TDB6/133RE136 RE SRT136 RE TDB6/136RE140 RE SRT140 RE TDB6/140RE141 AB SRT141AB-86,5 TDB6/141AB

24


Joint bar positioning gauges Positioning gauges MRFY for drilling Joint bar holes at pre-defined distances between rail end and holes center lines.

MRFY 10: Suitable for drilling the following rails 100 ARA-B, 115 and 119 REMRFY 11: Suitable for drilling the following rails 100 ARA-B and 105 DL&WMRFY 12: Suitable for drilling the following rails 115, 119, 132, 136, 140 LB RE, 130 and 155 PSMRFY 13: Suitable for drilling the following rails 80, 90 LB ASCE and 100 ARA-AMRFY 14: Suitable for drilling the 85 LB ASCE railMRFY 15: Suitable for drilling 130 LB RE and 136 LB LE. VAL railsMRFUY: Universal positioning gauge for all rail sizesMRFY 16C: For Canadian market

Please note: other positioning gauge sizes available upon request.

POSITIONING JIG MRF SR-SFA and MRF SR-SF

MRF SR-SFAThe MRF SR-SFA positioning jig is suitable for drilling the following hole centres in axle counter applications: - 2 holes with centres of 5.7 in.;- 2 holes with centres of 10.6 in.; - 3 holes with centres of 5.8 in..

MRF SR-SFThe MRF SR-SF positioning jig is suitable for drilling the following hole cen-tres in axle counter applications: - 2 holes with centres of 5.7 in.;- 2 holes with centres of 10.6 in.

MRF SR-SFA

MRF SR-SF

SR-SKISupport

SR...Templates KIT

25


Cembre Broach Cutters 2” Depth of Cut (To Be Used With Cembre PPL2 Pilot Bit)

01354 (7/8" hole diameter)01355 (15/16“ hole diameter) 01356 (1“ hole diameter) 01357 (1 1/16" hole diameter) 01358 (1 1/8" hole diameter) 01359 (1 3/16“ hole diameter) 01360 (1 1/4" hole diameter) 01361 (1 5/16“ hole diameter) 01362 (1 3/8" hole diameter) 01363 (1 7/16" hole diameter) 01364 (1 1/2" hole diameter)12218* (9/16" hole diameter)

Cembre Broach Cutters 3” Depth of Cut (To Be Used With 3-10528 Pilot Bit)

3-12224 (3/4" hole diameter)3-12226 (13/16" hole diameter)3-12228 (7/8" hole diameter)3-12230 (15/16" hole diameter)3-12232 (1" hole diameter)3-12236 (1 1/8" hole diameter)

Cembre Broach Cutters 7/8” Depth of Cut (To Be Used With Cembre PPC2 Pilot Bit)

15128 (7/8" hole diameter) 15130 (15/16" hole diameter) 15132 (1" hole diameter) 15234 (1 1/16" hole diameter) Cembre TSC 1 1/8" (1 1/8" hole diameter)15138 (1 3/16" hole diameter) Cembre TSC 1 1/4" (1 1/4" hole diameter)Cembre TSC 1 5/16" (1 5/16" hole diameter)15144 (1 3/8" hole diameter) 15146 (1 7/16" hole diameter) Cembre TSC 1 1/2" (1 1/2" hole diameter)Cembre TSC 3/4" (3/4" hole diameter)

Cembre Pilot Bits (For Use With Broach Cutters)

Cembre Pilot bit type PPDF2(to be used with 3” long cutters)

Cembre Pilot Bit type PP1(to be used with 1” long cutters)

Cembre Pilot Bit type PPL2(to be used with 2” long cutters)

Cembre Pilot Bit type PPC2(to be used with 7/8” long cutters)

Pilot Bit type 3-10528(to be used with 3” long cutters)

BROACH CUTTERS

These cutters rapidly produce high quality, accurate holes in a single pass. The auto-matic lubrocooling system reduces friction and eliminates heat build up during the drilling operation. Under standard condi-tions a broach cutter can drill 40-50 holes, depending on the hardness of the rail.

AOT ADAPTER FOR TWISTER BROACH CUTTERS

A new adapter for Cembre drilling machines has been specifically designed to accept broach cutters, already in use by customers, having the one-touch fixing system.This new adapter does not have any grub screw since broach cutter twister type are held in place by the special shape of their shaft.The broach cutter is fix into the adapter by an easy push & twist operation: push the cutter into the adapter and twist clockwise.In order to fix the AOT adapter to the drilling machine, proceed by tightening the 2 grub screws of the shaft, as commonly done to fix standard broach cutters.

AOT adapter requires the PPL2 Pilot Bit.

PUSH

TWIST

*special pilot bit required

Cembre HEN Carbide Cutters 7/8” Depth of Cut

CCQ 3/4-7/8 (3/4" hole diameter) CCQ 7/8-7/8 (7/8" hole diameter) CCQ 1-7/8 (1" hole diameter) CCQ 1 1/8-7/8 (1 1/8" hole diameter) CCQ 1 3/16-7/8 (1 3/16" hole diameter) CCQ 1 1/4-7/8 (1 1/4" hole diameter)CCQ 1 5/16-7/8 (1 5/16" hole diameter)CCQ 1 1/2-7/8 (1 1/2" hole diameter)

Cembre HEN Carbide Cutters 2” Depth of Cut

CCQ 1-2 (1" hole diameter)CCQ 1 1/2-2 (1 1/2" hole diameter)

Cembre HEN Carbide Cutters 3” Depth of Cut

CCQ 7/8-3 (7/8" hole diameter)

Other sizes available on request

26


SPECIAL APPLICATION FOR CEMBRE RAIL DRILLS

SPECIAL SPIRAL TWIST BITS

Using these bits guarantees optimum performance during the drilling operation. The semi-automatic lubrocooling system, reduces friction and eliminates heat build up during the drilling operation. As a rule, under normal conditions, a spiral bit can drill 70-100 holes, depending on the hardness of the rail.

* = APPLICATION DEVELOPED FOR NARROW CHAIRS 1 = FOR DRILLING 56 lb ALUMINUM BAR MANUFACTURED BY FOSTER2 = FOR DRILLING 84 lb ALUMINUM BAR MANUFACTURED BY FOSTER3 = FOR DRILLING 84 lb ALUMINUM BAR MANUFACTURED BY PORTER

Application Clamp Template Cutters Extension Pilot Bit

UIC 69* DBC AAT

01354 (7/8" hole diameter)01355 (15/16“ hole diameter) 01356 (1“ hole diameter) 01357 (1 1/16" hole diameter) 01358 (1 1/8" hole diameter) 01359 (1 3/16“ hole diameter) 01360 (1 1/4" hole diameter) 01361 (1 5/16“ hole diameter) 01362 (1 3/8" hole diameter) 01363 (1 7/16" hole diameter) 01364 (1 1/2" hole diameter)12218 (9/16" hole diameter)

PFA PPL4

150 LB TST 50 + DBG-AY MPAF 150 LB-3Y

3-12224 (3/4" hole diameter)3-12226 (13/16" hole diameter)3-12228 (7/8" hole diameter)3-12230 (15/16" hole diameter)3-12232 (1" hole diameter)3-12236 (1 1/8" hole diameter)

PFA 1 PPDF2

Aluminum-Rail-AluminumCOMPOSITE

TST 50 + DBG-AY

MPAF 56 CF COMP1

MPAF 84 CF COMP2

MPAF 84 CP COMP3

MPAF 85 LB ASCE

PE 130L-AR (1/2" hole diameter)PE 3/4"-L1-AR (3/4" hole diameter)PE 7/8"-L1-AR (7/8" hole diameter)PE 1"-L1-AR (1" hole diameter)PE 1 1/4"-L1-AR (1 1/4" hole diameter)PE 1 1/8"-L1-AR (1 1/8" hole diameter)

- -

27

EXAMPLE OF RAIL DRILLING MACHINE INSTALLATION

USE ON RUNNING RAILS

USE ON GIRDER RAIL (for example 128 or GGR 118)

STANDARD USEDBG-Y over rail clamp equipped with TDB- 6 termination

DRILLING BY THE GUARD RAILDBG-GR over rail clamp equipped with TDB-1 termination

• DBG-LY over rail clamp• Specific positioning template MPAF

• Use of 2” depth of cut broach cutters

The design of the shoe (combination)allows the positioning on both sides of the rails

28

AUTOMATIC RAIL DISC SAW

ROBOKATTA RDS-14P-AApresents a new concept in Rail Disc Saws by combining a powerful and robust Saw with the worlds first Automatic Support Arm which, during the cutting phase, allows the operator to be in control but away from the machine and therefore subject to:

• Vibration: Zero• Physical Effort: Zero• Harmful Dust: Zero• Sparks: Zero• Exhaust Fumes: Zero• Acoustic Noise: Minimum

Designed for precise cutting, Robokatta Automatic Rail Disc Saw has the perfectly perpendicular action essential for making the consistently accurate right-angle cuts in both axes that are fun-damental to the reliability of isolated joints in automatic signalling systems.

For traditional Manual operation, the alternative two-joint Support Arm combines simplicity with precision and minimises the working weight of the Saw for the operator.

Design features:

In both manual and automatic modes, Robokatta offers tremendous advantages over other rail saws including: • “Expert operator” cutting times and accuracy obtained due to: – Rigorously engineered support arms – Patented self-adjusting belt tension system• Speed control to optimise disc performance, minimising consumption

and consequently delivering the greatest number of cuts• Elastic system for vibration damping

• One-piece disc support arm and hub coupled to the fixing arm provides maximum rigidity and cutting precision

• Metallic disc protection casing with angular regulation device is not affected by vibration, so assures operator security and optimum visibility

• Transportation handle designed to assist motor protection • Automatic switch off at end of cut• Automatic alarm for air filter cleaning • Switch off the machine or reset the air filter cleaning alarm via

the Auxiliary Switching Device supplied.

29

AUTOMATIC RAIL DISC SAW

PATEN

T PEND

IN

G •

AA-RDS automatic support arm

• Powered by the rail saw engine to simulate the movement of a skilled operator during the cutting phase

• Original clamp configuration for better and safer coupling to the rail being cut

• Exact cutting position indicator integrated into the clamp • Ability to invert the rail saw easily and quickly to continue cutting

on the other side of the rail, without relocating the clamp and support arm

• Arm joint supported by shielded bearings & assembled with no end float to ensure precision when cutting from both sides of the rail

• May be blocked in “Hold” position to simplify rail saw location and start-up operations

• Can be switched to manual mode.

Technical characteristics:

ROBOKATTA RDS-14P rail saw• Husqvarna 2-stroke engine with electronic start and 5 stage air

filter; 7.9 HP (5.8 kW) at 9750 rpm • Pulley transmission with centrifugal clutch and trapezoidal tooth belt• Tank capacity: 0.33 Gal • Cutting disc diameter: 14"/16"• Disc support shaft diameter: 1"• Dimensions (without disc) - Length: 31,4"- Width: 11,27"- Height: 17,3"• Weight:- Without support arm: 41.9 lbs- Weight of manual support arm: 18.7 lbs- Weight of automatic support arm: 43.6 lbs

“Expert operator” cutting times and accuracy in automatic and manual modes

Auxillary switching device

Optional accessories:

VAL RDScase for storage of the RDS-14P rail saw.

VAL AA-RDScase for storage of the AA-RDS automatic support arm.

Cutting discs For ROBOKATTA best performance use Cembre C-REX cutting discs:

CRDL4387 (14” x 7/8”) CRDL4381 (14” x 1”) CRDL6407 (16” x 7/8”) CRDL6401 (16” x 1”)

SA-RDS manual support armSupport arm for using ROBOKATTA in manual mode only.

RDS-14P rail disc saw

Consult us for ROBOKATTA version equipped with 7/8” diameter disc support shaft

SSR1stabiliser support for short rail lengths.

30

SUPPORT TROLLEY

The trolley is easily assem-bled and can comfortably be carried by a single operator.

Portable drilling machines for wood ties SD-15PR-ECO + support trolley CS-SD

800

1650

120

430

1075

Portable gas engine impact wrench NR-11P + support trolley CS-SD

General features:

• Weight: (without connecting rod) 38.5 lbs• Connecting rod weight: 26.4 lbs

• Dimensions (in.):

CS-SDCS-SD-TAThe support mechanism, which secures the portable drilling machines SD-15PR-ECO, SD-10E-110 and the portable impact wrenchs NR-11P and NR-13E-110, incorporates a gas pressure spring to give a constant, balanced control to the machine during operation. Fitted with insulated wheels, the trolley does not interfere with the track electrical circuits. The trolley is easily closed and can comfortably be carried by a single operator.The CS-SD standard version is suitable to work on standard gauge rails (4ft 8.5in), while the CS-SD-TA is the adjustable version suitable to cover gauges from 3ft 3.4in to 5ft 7in.

PATENTED • PATE

NTE

D •

31

KCS-NR interface kit for vertical use with support trolley CS-SD

KHOR-NR interface kit for horizontal use with support trolley CS-SD

IN HORIZONTALIN VERTICAL

POSSIBILITY OF EMPLOYMENT OF PORTABLES IMPACT WRENCH NR-11P AND DRILLING MACHINE FOR WOOD TIES SD-15PR-ECO WITH SUPPORT TROLLEY CS-SD

KEB-NR extension kit to be installed on the existing KCS-NR kit, suitable to raise the standard working level of the NR-11P. Designed for road crossings applications.

IN ROAD CROSSINGS

SUPPORT TROLLEY ACCESSORIES

KCS-SD-RCInterface kit specifically designed for road crossing applications to be installed on existing support trolley CS-SD.

IN BRIDGES

KLE-32-CSKLE-43-CS Extensions to be used on support trolley CSSD allowing Drilling or Lagging of Timber Guard Rails Up to 43” From Field Side for both tie drill and nut runner.

Long one up to 43” from field sideShort one up to 32” from field side

32

PORTABLE - TWO CYCLE GAS ENGINEIMPACT WRENCH NR-11P

HIGH TORQUE

1844 ft. lbs

NR-11P

Ideal for Railways, Construction sites,Oil and Mining Industries, Shipyards.

PATENTED • PATE

NTE

D •

General features:

X - Fuel TankThis large tank has a 0.3 Gal. capacity for longer working time between refills. The gripping surfaces on the cap make it easy to remove/replace and the facility to add fuel in both vertical and horizontal positions avoids accidental spillage.

Y - HandlebarCareful ergonomic design of the machine spreads the weight equally between left and right handles. The structure formed by the combination of the shaped handle bar and the protective shield minimise the risk of accidental mechanical shock to the fuel tank and engine.

Z - Control handleControl buttons are specifically located to reduce the effects of working in awkward positions, eg wrist and shoulder discomfort, thereby optimising performance in both vertical and horizontal modes, while a Dead man device prevents accidental acceler-ation, for operator safety. The control handle assembly is clamped to the handlebar via a steel rod for enhanced robustness.

[ - Trolley (see pages 30-31)Optional interface kits enable the machine to be used in vertical and horizontal modes with the rail mounted CS-SD support trolley. Fitted with a braking device in accord-ance with EN19277, the trolley eliminates much of the effect of the weight of the machine and allows rapid movement between work areas.

\ - Gearbox Brightened steel gears are immersed in a synthetic oil bath to prolong life and extend the range of permitted working temperatures. The gear change lever is adjacent to the accelerator control in order to avoid damage caused by changing gear while the engine is running. Smooth acceleration is provided by the centrifugal clutch.

] - Impact mechanism The innovative patented impact unit develops a high torque and has a larger impact surface than any other nut runner, so to extend the life of this essential component. Specialist, high spec grease minimises wear in this area and the special seal on the drive prevents the leakage of grease commonly seen on other impact wrenches.

^ - Engine With a greater impact surface, the NR11P does not need higher rpm to develop 2500 Nm thus the engine is not continuously straining at maximum rpm, allowing maintenance intervals to be extended.

_ - Vibration The handlebar is mounted on 4 vibration absorbing dampers so to reduce hand-arm vibration felt by operators.

` - Easy-start With its decompression button, primer and digital ignition coil, minimum time and effort are required to start NR11P.

Protective shieldTo protect tank

and engine from accidental shocks

Torque selectorWith 5 positions

Forward/Reverse selector

Smooth change

Z

Y

X

[

`

\

]

_

^

33

PORTABLE ELECTRIC IMPACT WRENCHNR-13E-110

HIGH TORQUE

1844 ft. lbs

PATENTED • PATE

NTE

D •

NR-13E-110

Technical Features:• Engine: single phase electric motor• Supply voltage: 110÷120 V / 50÷60 Hz• Power rating: 2.8 kW• Weight: 46.3 lbs

The NR-13E-110 is suitable for use with the CS-SD support trolley (see pages 30-31)

Fitted with PRCD device (Portable Residual Current Device)

ACOUSTIC NOISE (Directive 2006/42/EC, annexe 1, point 1.7.4.2 letter u)Protection of workers against risks of exposure to noise during work.

NR-11P– The weighted continuous acoustic pressure level equivalent A at the work place LpA is equal to ........................................................... 96,2 dB (A)– The maximum value of the weighted acoustic displacement pressure C at the work place LpCPeak is equal to ......................................... 123,9 dB (C)– The acoustic power level emitted by the machine LWA is equal to ..................................................................................... 108,9 dB (A)

NR-13E-110– The weighted continuous acoustic pressure level equivalent A at the work place LpA is equal to ........................................................... 98,4 dB (A)– The maximum value of the weighted acoustic displacement pressure C at the work place LpCPeak is equal to ......................................... 123,6 dB (C)– The acoustic power level emitted by the machine LWA is equal to ..................................................................................... 107,2 dB (A)

RISK DUE TO VIBRATION (Directive 2006/42/EC, annexe 1, point 2.2.1.1).Tests carried out in compliance with the indications contained in UNI ENV 25349 and UNI EN 28662 part 1st Standards, 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 respectively:

NR-11P8,68 m/sec2 max

NR-13E-1107 m/sec2 max

PROTECTION AND SAFETY AT WORK OF IMPACT WRENCHS

34


MAIN SPECIFICATION

ENGINE Type: Two cycle, forced-air cooled, single cylinder Displacement: 55 cc Fuel tank capacity: 0.3 USA Gal Fuel mixture ratio:

Synthetic oil 1:50 2 cycle mineral oil 1:25 Revolution (idle): 2800 rpm ± 200 Revolution (loaded, impact): 7000 rpm Revolution (non loaded, max): 11500 rpm

IGNITION Type: Digital Spark plug type: RAX 80 or equivalent

CARBURETTOR Type: Diaphragm

IMPACT UNIT Square driver size: 1” Fastening torque range: Full Throttle: 1844 ft. lbs

MANDREL SPEED No load: 1300 rpm

WEIGHT Dry: 41 lbs

{

DIMENSIONS inches

25.2

10

.81

6.9

35

MAIN APPLICATIONS:

Assembly of steel structures such as bridges, building frames, rail tracks, ship building, heavy equipment maintenance, pipelines and industrial applications.

The protective handlebar structure facilitates a comfort-able dorso-lumbar operating position without wrist injury.

Anti-vibration couplings reduce trans-mission of vibration to the operator.

A reduced mandrel axis to ma-chine base dimension facilitates a more convenient horizontal position for working with track bolts, even when operating across sleepers.


OPTIONAL ACCESSORIES:

Ref. Description

XT 100 1” x 4” (length) extension

SJ 1” 1” swivel joint

CLIP NR Retaining circlip for fastening sockets to the mandrel.

KCS-NR Kit for mounting NR11-P to CS-SD support trolley.

KHOR-NR interface kit for horizontal use with support trolley CS-SD

KEB-NR extension kit designed for road crossings applications.

CS-SDSupport trolley common to NR11-P and sleeper drilling machines SD-15PR-ECO and SD-10E-110.

VAL P20 Plastic box for storage of sockets and accessories.

VAL NR Steel case for storage of NR11-P and VALP20 acces-sories box.

TARPCOVER027-NR

Protection cover manufactured in Polyethylene HDPE and UV resistant. Temperature range: -40°C to +70°C.

Standard and long impact sockets, extensions, swivelling shaft, adapters.

CLIP-NR 57

Retaining circlip for fastening sockets to the mandrel having an external diameter range: 1.85”÷2.24”. 3 pieces supplied as standard.

Retaining circlip for fastening sockets to the mandrel having an external diameter range: 2.24”÷2.64”. 1 piece supplied as standard.

CLIP-NR

TARPCOVER 027-NR

VAL P20VAL NR

36

PORTABLE TWO CYCLE GAS TIE DRILL WITH FORWARD AND REVERSE FEATURE

General features:Two cycle engine:• Displacement: 53,2 cc• Power: 2.7 HP/ 2.0 kW• Fuel: 2% mixture (1:50)• Starting: rope pull with automatic rewind.• Clutch: centrifugal clutch with automatic intervention• Bit diameter range: up to Ø 25/32” *• Max drilling thickness: 7 7/8”• Weight: 44.0 lbs

* Depending on the type of wood it is also possible to drill larger holes

• co

nforming to • EN13977

conforming t

o

TWO CYCLE GAS ENGINE SD-15PR-ECO

! - AcceleratorAccelerator lever fitted with safety switch to prevent accidental operation.

" - Centrifugal clutchFitted with a centrifugal clutch; with the engine running at ‘idle’ speed the drill bit is stationary. The accelerator controls the rotation of the drill bit.

# - Operating handleHandle will rotate through 90° for operator comfort.

$ - Emergency lever Emergency lever for the immediate release of the drill bit.

% - Shock absorbers Shock absorbers fitted between the drive shaft and spindle, reduce the transmis-sion of machine vibrations to the operator.

& - Carrying handle (see page 39)Carrying handle; also used for locating the drilling machine into the CS-SD trolley.

' - Depth gauge Depth Gauge; easy to operate using the graduated scale, for adjusting the depth of drilled hole.

( - MND spindle MND spindle, for automatically securing drill bits, with a 0.55 in. (14 mm) diameter shank.

) - MND1 interchangeable spindle MND1 interchangeable spindle: Available as an optional accessory.For automatically securing drill bits, with a 0.63 in. (16 mm) diameter shank.

* - Safety guard Safety guard: providing effective, total protection of the drill bit 12.8 in. (325 mm). Spring loaded to guarantee the retraction of the drill bit from the sleeper on com-pletion of the drilling operation, thereby minimising operator effort.

+ - Guard nozzle Interchangeable, Guard Nozzle TPM200-26, for locating into chairs and base plates, as commonly used on existing tracks.

, - Engine New engine conforming to “phase 2” of 97/68/CE, 2001/63/CE and 2002/88/CE directives.

- - Forward/Reverse selector Reverse action enables easy withdrawal of auger.

PATENTED • PATE

NTE

D •

According to phase 2European Directives

New

.

"#

$

&

/

'

0

)

*

-

+

,

37

PORTABLE DRILLING MACHINES FOR WOOD TIES TYPESSD-15PR-ECO AND SD-10E-110

ELECTRIC SD-10E-110

General features:• Engine: single phase electric motor• Supply voltage: 110-120 V / 50-60 Hz• Power rating: 1.8 kW• Bit diameter range: up to Ø 25/32” *• Max. drilling thickness: 7 7/8”• Weight: 38 lbs

* Depending on the type of wood it is also possible to drill larger holes

PATENTED • PATE

NTE

D •

• co

nforming to • EN13977

conforming t

o

PROTECTION AND SAFETY AT WORK OF DRILLING MACHINES

The SD-10E-110 is suitable for use with the CS-SD support trolley (see pages 30-31)

ACOUSTIC NOISE (Directive 2006/42/EC, annexe 1, point 1.7.4.2 letter u)Protection of workers against risks of exposure to noise during work.

SD-15PR-ECO– The weighted continuous acoustic pressure level equivalent A at the work place LpA is equal to ........................................................... 97,9 dB (A)– The maximum value of the weighted acoustic displacement pressure C at the work place LpCPeak is equal to ......................................... 116,9 dB (C)– The acoustic power level emitted by the machine LWA is equal to ..................................................................................... 106,5 dB (A)

SD-10E-110– The weighted continuous acoustic pressure level equivalent A at the work place LpA is equal to ........................................................... 93,1 dB (A)– The maximum value of the weighted acoustic displacement pressure C at the work place LpCPeak is equal to ......................................... 130 dB (C)– The acoustic power level emitted by the machine LWA is equal to ..................................................................................... 104,3 dB (A)

RISK DUE TO VIBRATION (Directive 2006/42/EC, annexe 1, point 2.2.1.1).Tests carried out in compliance with the indications contained in UNI ENV 25349 and UNI EN 28662 part 1st Standards 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 respectively:

SD-15PR-ECO7,06 m/sec2 max

SD-10E-1103,7 m/sec2 max

38


Augers for Cembre tie drills

TPM...Guard Nozzle for the moveable guard, interchangeable with the standard nozzle.

5/8” ADAPTERkey chuck with spindle adapter enables the use of other styles of tie drill bits.

Cembre Carbide Counter Bit 1 1/2" For the PV 180

VAL P 6Plastic case for storing the drill bits and standard accessories supplied with the machine. This case can be stored inside the drilling machine case.

VAL SDRobust steel case for storing the drilling machine and VAL P6 accessory case.

TARPCOVER 026-SDProtection cover manufactured in Polyethylene HDPE and UV resistant.Temperature range: -40°C to +70°C.

OPTIONAL ACCESSORIES FOR WOOD TIES DRILLING MACHINES

TARPCOVER026-SD

VAL SDVAL P6

TPM...

5/8” Adapter

Cembre Type DiameterIn. (mm)

LenghtIn. (mm)

GUARD NOZZLE TPM...Standard Optionals (available on request)

PV 7/16" 7/16" (11)

12.8 (325) TPM

200

-26

TPM

170

-24

TPM

190

-24

TPM

220

-26

PV 140 9/16" (14)PV 160 5/8" (16)PV 170 43/64" (17)PV 180 11/16" (18)PV 190 3/4" (19)PV 200 25/32" (20)PV 210 13/16" (20)PV 220 7/8" (22)

PV 170/220 43/64" (17) - 7/8" (22)Contac Cembre for different applications, or for drilling operations, where an alternative size, end piece is required.

CarbideCounterBit 1 1/2"(to be used with PV180)

39


The SD-15PR-ECO unit ena-bles vertical holes to be drilled quickly and efficiently.If required, the angle of the Spindle Axis can be adjusted up to 5°. The unit can quickly and easilybe removed from the track.

This new, patented unit has been designed and developed by Cembre, to provide optimum safety, both when using the drilling machine independently and with the machine fitted onto the trolley.Compact and lightweight, the unit can be positioned and operated by a single person.

The unit is easily assembled and can comfortably be carried by a single operator.

Example of use on double crossovers.

Easily combined with Support Tolley CS-SD

Two stroke petrol engine machine,purpose built for use withthe support trolley CS-SD

40

PANDROL ‘‘E CLIP’’ MACHINE

PCM-2P/UPCM-2P/U1PCM-2PFor “e” type PANDROL CLIPS

Rapid performance with a high de-gree of simplicity of use, requiring only one operator. Suitable to insert & extract “e” type Pandrol clips on both sides of the rail at the same time. A single operator can easily manage the machine.

Typical application on which the PCM-2P/U is used: long baseplate (7.87 in.) on wooden ties.

"E" Clip Applications on both Wooden and Concrete Ties.

PCM-2P/U... is equipped by a mechanical stop device guaranteeing that all the clips are fixed properly in the same way avoiding overdriving. The device is quickly removable so to allow the extraction of clips.

Easily adjustable to work both on wooden and concrete ties (long and short baseplate version) on several rail types.

Inserction and extraction of the clip by means of the PCM-2P/U1

PCM-2P/U

Typical application on which the PCM-2P/U can be used: Short baseplate (2.76 in.) on concrete ties, Available upon request a special machine PCM-2P specific just this application.

PCM-2P

Typical application for the PCM-2P/U1: special metro baseplate on concrete ties or basement.

PCM-2P/U1

Braking system PCM-2P-BRAKED meets the requirements of EN13977.

41

PANDROL ‘‘E CLIP’’ MACHINE

PUMP UNIT

CLAMP UNIT

TROLLEY UNIT

• The PCM-2P/U... machine from Cembre is suitable for the insertion and extraction of “e” type pandrol clips used with 2.76 in. & 7.87 in. bases;

• The unit is immediately ready to use requiring no assembly or disas-sembly of accessories;

• Particularly suited to rail adjustment work, for instance on in-progress rail sections or track renewal, the PCM-2P/U... & PCM/2P machines also generally applicable in maintenance operations.

• Ballast on ties does not unduly affect the machine, as the clamp do not rest on them;

• The pump unit is the same as that used on PCM-2P/U, PCM-2P/U1, PCM-2P/FC and PCM-2P guaranteeing and high versatility in case of several applications.

• The pump unit is suited by a sturdy and powerful 4-stroke engine, Honda or equivalent, with noise levels according to CARB-EPA standards.

• Does not interfere with rail circuits due to the three insulated wheels;• Compactness and easy transport makes the PCM-2P/U... machine

a very reliable for the immediate use. • Weight: Pump unit 108 lbs, Clamp unit 106 lbs , trolley unit 20 lbs ,

wheel bar 11 lbs• The self-braking system is quick & easy to connect and intervenes

automatically when the operator releases the handle of the machine.

GENERAL FEATURES

ASSEMBLY SEQUENCE PCM-2P/U..

4

2

3rd WHEEL BAR

3

1

direction of operation

Easy assembly and transpor-tation by two persons.

PCM-2P

PCM-2Pspecific just for 2.76 in. bases on concrete ties.

3rd wheel bar suitable to work on standard gauge rails (4ft 8.5 in.). Available upon request the adjustable version suitable to cover gauges from 3ft 3.4in to 5ft 7in.

1 2 3

42

PANDROL ‘‘FAST CLIP’’ MACHINE

• The pump unit is the same as that used on the Pandrol ‘‘e clip’’ machine (see page 40) and consequently owners of the PCM-2P need purchase only the clamp unit.

• Easy disassembly allowing operators to work safely on uneven ground.

• The unit is immediately ready to use requiring no assembly or disas-sembly of accessories.

• Rapid performance with a high degree of simplicity of use requiring only one operator.

• Simultaneous insertion or extraction of two clips by two independent clamps.

• ‘‘Fast clips’’ located on one side of the rail may be inserted or ex-tracted when there are no clips on the opposite side.

• Possible to work with only one of the clamps, either for insertion or extraction, to operate if necessary on only one side of the rail.

• The pump unit is the same as that used on the ‘‘e’’ clip machine, incorporating a sturdy and powerful 4-cycle engine, Honda or equivalent, with noise levels according to CARB-EPA standards.

• Does not interfere with rail circuits due to the three insulated wheels and is also equipped with an appropriate mechanical joint to allow running without interference on the rail to reach the working area.

• Equipped with spot lights oriented to the working areas.• Weight: Pump unit 108 lbs, Clamp unit 145 lbs, Trolley unit 20 lbs,

3rd wheel bar 11 lbs.• The self-braking system is quick & easy to connect and intervenes

automatically when the operator releases the handle of the machine.

GENERAL FEATURES

Extraction and insertionof Pandrol ‘‘fast clips’’.

For PANDROL “FAST CLIPS” The Pandrol "Fast Clips" machine from Cembre is suitable for the insertion and extraction of Pandrol ‘‘fast clips’’ used with all 4 ft 8.5 in. gauge standard rails mounted on monoblock or biblock concrete ties.

This Pandrol "Fast Clips" machine version is also equipped with a rapid and easy to use fine adjustment system allowing the ‘fast clip’ to be positioned in either the pre-assembled parked position, the fully inserted/removed position or the insulator change position, as shown in the figs alongside.

INSTALLED POSITION

PARKED POSITION

SHOULDER

TOE INSULATOR

FASTCLIP

POSITIVE LOCK-IN

INSULATOR CHANGING POSITION

Braking system Pandrol "Fast Clips" machine meets the requirements of EN13977.

43

PANDROL ‘‘FAST CLIP’’ MACHINE

TARPCOVER 019-PCMRobust UV resistant cover for PCM machines.Temperature range: -40°C to +70°C.

MPC 6Manometer for checking the operation of the maximum pressure value in the hydraulic circuit.

PUMP UNIT

CLAMP UNIT

ASSEMBLY SEQUENCE

direction of operation 2

4

1

TROLLEY UNIT

OPTIONAL ACCESSORIES FOR PANDROL CLIP MACHINES

3rd WHEEL BAR

33rd wheel bar suitable to work on standard gauge rails (4ft 8.5 in.). Available upon request the adjustable version suitable to cover gauges from 3ft 3.4in to 5ft 7in.

56

44

Contact wire cut with a traditional cutter

Contact wire cut with the RH-TFC hydraulic head

Hydraulic RH-TFC head with in-terchangeable dies to perform a perfectly perpendicular cut without deformation of the wire shape (see page 45 for the selection of the available tools).

The joint allows connection between new or new and worn contact wires without any tapering operation, as-suring a uniform and continuous sliding area of the pantograph; the use of these joints also reduces interven-tion times to a minimum. In addition to the laboratory tests, on line tests have shown that the joint operates satisfactorily on 180 km/h lines and on lower speed lines but with strong current absorption (gradients).

CONNECTING JOINT TYPE

TORQUE RATIO Nm

GROOVED CONTACT WIRE

Section (mm2) Ø (mm) REFERENCE STANDARD

FTGW 100

65

100 12,0EN 50149

(Type AC-120 or Cu and CuAg 0,1)

FTGW 120 120 12,913,2

FTGW 150 150 14,5

The jointing process can be improved and made quicker by the perpendicular cutting of the contact wire ends to be joined using the appropriate tool:

DIE SETSA wide range of dies is available tocut most profiled contact wires or stranded conductors.

For further information contact the local Cembre office.

Hydraulic cutting head for cutting profiled contact wires and copper and aluminium ropes. Interchangeables dies cut perpendicularly and without deformation to optimise joint installation.

The use of this head simplifies the cutting operation and reduces the time needed to prepare the joint.

For use with any of the following 10,000 psi hydraulic pumps:HTP, manually operatedPO-7000, foot operatedB70M-P24A portable electro-hydraulic 24V DC motor driven, powered by internal battery or external supply.

CONNECTING JOINTS FOR PROFILED CONTACT WIRES

HYDRAULIC CUTTING HEAD RH-TFC

PATEN

T PENDIN

G

•

Suitable for 4/0 AWG contact wire

MFC cutting die sets availableContact Wire Type Cutting DiesCu/Steel conductor MFC-D7.5-S

Cu or Al Round rod Ø 10.8 MFC-D10.8Cu or Al Round rod Ø 14.5 MFC-D14.5Cu or Al Round rod Ø 16.1 MFC-D16.1

2/0 AWG MFC - 2/0 AWG4/0 AWG Grooved MFC - 4/0 AWG300 MCM Grooved MFC - 300 MCM335 MCM Grooved MFC - 335 MCM350 MCM Grooved MFC - 350 MCM

45

HYDRAULIC CUTTING TOOLS TYPE RH-TFC, HT-TFC, B35-TFC FOR PROFILED CONTACT WIRE

HT-TFC This two speed lightweight and compact, hydraulic tool is ideal for cutting profiled contact wires, on electrified traction systems. Having the benefit of spring loaded handles, the dies can be advanced using only one hand. For ease of operation and comfort of the operator, the tool head can be rotated through 180 degrees. The built-in safety valve will by-pass the oil supply when the maximum pressure is reached, and a pressure release system can easily be operated at any stage of the compression.

B 35M-TFCThe B 35M-TFC is a cordless tool that can be operated with one hand. Suitable for cutting profiled contact wires, on electrified traction systems.• balanced tool for greater control• Head rotates 180° for ease of operation in confined spaces.• Fitted with a maximum pressure valve.• Automatic return of dies after completion of the cut.• Automatic return can be stopped at any time to ease positioning.• Extremely quiet, minimal vibration.• Durable moulded body offering high resistance to wear and

damage in all operating conditions.• New Li-Ion 18V 2Ah High Power battery.• The battery is equipped with LED indicators to show the re-

maining battery life at any time by pressing the adjacent button.• Supplied in a robust plastic case to accommodate the tool and

all the accessories. • Two batteries and AC charger (110-115V) included.• Operating temperature: +5 to +122°F

RH-TFCHydraulic presshead com-plete with quick automatic coupler for connection to a hydraulic pump with a max working pres-sure of 10,000 psi. Suitable for cutting profiled contact wires, on electrified traction systems.

1

2

1

2

3

3

�

�

�

� Insert the die set into the head.

� Position the conductor inside the die set so that the blade lines up with the desired cutting point; close the die set by moving the locking handle towards the tool body, until automatically “locked” in position and securely clamping the wire/conductor.

� Operate the pump to advance the blade to the conductor; the blade progressively advances until the conductor is completely cut in a clean and precise manner without deforming the conductor itself.

Simple 3 stage operation

Cutting capacity (diameter max.): 0.79 in.Max operating pressure: 10,000 psiDimensions:length 7.72 in.width 6.26 in.Weight 6.82 lbs

Cutting capacity (diameter max.): 0.79 in.Max operating pressure: 8,600 psiDimensions:length 14.7 in.width 10.121 in.Weight 7.92 lbs

VAL P43Supplied in a robust plastic case VAL P43suitable for storage of the tool and 3 sets of dies.- Dimensions 19.8 x 15.0 x 5.4 in. - weight 5.7 lbs

VAL P17Supplied in a robust plastic case VAL P17suitable for storage of the tool and 4 sets of dies.- Dimensions 18.5 x 15.1 x 4.3 in. - weight 4.4 lbs

Cutting capacity (diameter max.): 0.79 in.Max operating pressure: 6,500 psiDimensions:length 15.2 in.width 7.7 in.height 5.2 in.Weight 7.5 lbs

Available upon request:CINV 12-110IC, 12V car power inverter(see page 50)

VAL P15Supplied in a robust plastic case VAL P15 suitable for storage of the head and 4 sets of dies.- Dimensions 12.4 x 11.8 x 3.7 in. - weight 2 lbs

New

18V Li-Ion B A T T E RY

NEW

46

GROOVED CONTACT WIRE ALIGNMENT DEVICE DURING THE INSTALLATION OF CONNECTING JOINTS

AD-GWThis device is designed to facilitate accurate, repeatable and secure operations when aligning two grooved contact wires during the installation of connecting joints.Included with AD-GW is the HC-GW device designed to simplify radial and lateral adjustment of the contact wire to ensure rapid processing. AD-GW is equipped with hooks for easy attachment to self-gripping clamps and a Tirfor type mechanical ratchet block commonly used for tensioning contact wire in jointing operations.

By the HC-GW adjusting device you have to align the grooves of the new contact wire into the profile of the guide wheels and afterwards to tighten the AD-GW knob (on the tirfor side).

If necessary, use the adjusting device to correct the bend of the ends of both grooved contact wires.

Grooved contact

wire

Guide wheels

SELF-GRIPPING CLAMP TIRFOR

New contact wireContact wire to be retained

Contact wire to replace

Cutting point

Hook

SELF-GRIPPING CLAMP

Hook

HC-GW

AD-GW

AD-GWLsuitable to install long type contact wire joints having a maximum length of 14.76 in. The maximum tension weight admitted is 4.950 lbf.

AD-GWL

47

MECHANICAL STRAIGHTENING DEVICE FOR GROOVED CONTACT WIRES

MSGWThe mechanical straightening device for profiled contact wires, from 2/0 to 335 MCM, allows the easy and continuous straightening of the most common sizes of wires.

MSGW-E1For trolley wire 350MCM and larger

General features:• Dimensions inches:

17

9.2

11

.4

• Weight: 15 lbs

Die sets to be used with ECW-H3D hydraulic head.By a combination of the calibrated profile of these dies and the high compression force of the press head, good results in correcting localised mis-shaping of the wire may be obtained, with only one operation.

PROFILE STRAIGHTENING DIES4/0 AWG Grooved MSGW 110CN-4/0AWG-3D2/0 AWG Grooved MSGW 2/0AWG-3D335 MCM Grooved MSGW 335MCM-3D350 MCM Grooved MSGW 350MCM-3D

48

• Requires connection to a pump developing 10,000 psi pressure• Lightweight and compact, designed for ease of operation, for a

variety of applications.• The blade can easily be replaced

Application field:suitable for splitting nuts from 1-1/16" (M 18)

to 1-5/8" (M 27) hexagon

Working pressure: 10,000 psiWeight: 10.1 lbs

RHTD 3241

RHTD 1724Application field:suitable for splitting nuts from 5/8" (M 10)

to 1-1/16" (M 18) hexagon


B-TD1724A 14.4 V battery operated hydraulic tool suitable for splitting fastening bushes, hexagonal and square nuts as per RHTD 1724.

VAL P4RHTD1724, RHTD3241 are supplied in a sturdy plastic case suitable for storing the tool and accessories

HYDRAULIC NUT SPLITTING HEAD

SINGLE BLADE HEADS & BATTERY OPERATED UNIT

49

HYDRAULIC NUT SPLITTING HEAD

• Requires connection to a pump developing 10,000 psi pressure.• Lightweight and handy; its shape and dimensions have been de-

signed for the best comfort of operation in a variety of applica-tions.

• The blades can be easily replaced in case of damage.• Supplied in a sturdy plastic case suitable for storing the tool and

accessories.

Application field:

Suitable for splitting square and hexagonal nuts or fastening bushes as indicated in the table below


RHTD 3241T

B-TD3241TA 14.4 V battery operated hydraulic tool suitable for splitting fastening bushes, hexagonal and square nuts as per RHTD 3241T.

DOUBLE BLADE HEAD & BATTERY OPERATED UNIT

1-1/16" 45/64" 1-1/16" 45/64" 1/2" 0.807" 1-17/64" 55/64" 1-17/64" 55/64"1-3/16" 25/32" 1-3/16" 25/32" 5/8" 1.010" 1-11/32" 55/64" 1-27/64" 15/16"1-17/64" 55/64" 1-17/64" 55/64" 3/4" 1.200" 1-27/64" 15/16" 1-39/64" 1-1/16"1-11/32" 55/64" 1-27/64" 15/16" 7/8" 1.375" 1-39/64" 1-1/16"1-27/64" 15/16" 1-39/64" 1-1/16" 1" 1.575"

1-5/8" 1-1/16" 1-1/8" 1.770"

VAL P4RHTD3241T is supplied in a sturdy plastic case suitable for storing the tool and accessories

ar 60d - deltaline...hand held hydraulic installation kit for setting the cembre bonding bush ( ar...

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