RAIL WEB ELECTRICAL CONNECTION SYSTEM FOR RETURN TRACTION AND GROUNDING APPLICATIONS AR 60D. Lug

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1 RAIL WEB ELECTRICAL CONNECTION SYSTEM FOR RETURN TRACTION AND GROUNDING APPLICATIONS AR 60D Screw with (1 Piece) hollow hex head Copper bush Flat steel washer AR 60D Selflocking nut Lug ATENTED PPATENTED Electrical Permanent Contact for rail web type AR 60D for hole diameter 3/4 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 caractheristics 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). After extensive tests, either in laboratory or in the field, the system has been recognized as totally reliable and perfectly matching the above listed requirements. System components are as follows: a Electrolytically tin-plated copper bush type AR 60-1 b Steel M12 screw with hollow hex head (1 piece) c Flat steel washer d Self-locking nut To be installed by: Hydraulic tool type HTEPE-DETY or tool type RHTEP a d c b 2

2 AR 60D ASSEMBLY inch Ø inch AR 60D 17/32" 11/16" 3/4" CAL OG 13.2 OK NO HTEPE-DETY or RHTEP 3

3 RAIL WEB ELECTRICAL CONNECTION SYSTEM FOR SIGNALLING DEVICES AR 69D Steel M6 screw with (1 Piece) hollow hex head Copper bush Flat steel washer AR 69D M6 Selflocking nut Lug ATENTED PPATENTED Electrical Permanent Contact for rail web type AR 69D, for hole diameter 3/8" 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 plating b Steel M6 screw with hollow hex head c Flat steel washer d M6 self-locking nut To be installed by: Hydraulic Tool type HTEPE-DETY or RHTEP (using installation kit type AR69-INST) or hand held ratchet tool Type MTE1 d c a b 4

4 AR 69D ASSEMBLY inch Ø inch AR 69D 17/32" 11/16" 3/8" CAL OG 6.5 M9M5 OK NO HTEPE-DETY, RHTEP or MTE1 5

5 RAIL WEB CABLE CONNECTION SYSTEM DOUBLE CONTACT BUSH TYPE AR 260D AR 280 Stainless steel Bolt AR 260D AR 280* ATENTED PPATENTED Electrolytically tin-plated copper bush Stainless steel flat washers Stainless steel self-lock nut *AR 280 with copper lug 2A48-M14 approved by NEW YORK CITY TRANSIT AUTHORITY Cable lugs Electrolytically tin plated copper alloy washer System components are as follows: AR 260D a Electrolytically tin-plated copper bush type AR b Electrolytically tin-plated copper alloy washer type AR c M12x70 flat steel bolt d M12 stainless steel flat washer e M12 stainless steel self-lock nut AR 280 a Electrolytically tin-plated copper bush type AR b Electrolytically tin-plated copper alloy washer type AR c M14x70 flat steel bolt d M14 stainless steel flat washer e M14 stainless steel self-lock nut To be installed by: hydraulic tool type HTEPE-DETY or RHTEP for AR 260D (HTEPY for AR 280) Installation Tool a b c e d d CABLE CONNECTION ASSEMBLY RAIL WEB CABLE CONNECTION APPLICATIONS Traction return bonding Continuity bonding Signal track circuit connection Ground bonding 6

6 AR 260D and AR 280 ASSEMBLY inch Ø inch AR 260D 17/32" 11/16" 3/4" CAL OG 13.2 AR 280 9/16" 5/8" 1 1/8" CAL OG 15.2 OK NO HTEPE-DETY or RHTEP for AR 260D (HTEPY for AR 280) 7

7 SINGLE SIDE BONDING SYSTEM FOR CONTINUITY AND EARTHING APPLICATIONS AR 61E AR61DE AR 61E AR 61DE Railweb thickness: between 0.31" to 0.87". This unique system was developed by Cembre in response to a requirement for a version of the rail web bonding system, which could be installed in situations where access 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 ATENTED PPATENTED Electrical Permanent Contact for rail web type AR 61E and AR61DE for hole diameter 7/8 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 System components are as follows: a a Electrolytically tin-plated copper bush type AR 61E-1 b M12 steel expansion bolt c locking washer d M12 stainless steel self-lock nut b c d To be installed by: Hydraulic tool type RHTEPE-12-E and BAS-19 BAS-19 RHTEPE-12-E TERMINAL LUG 8

8 AR 61E and AR61DE ASSEMBLY inch Ø inch AR 61E 0.49" 0.87" AR 61DE 0.31" 0.49" 7/8" CAL OG 13.2 FASTENER ASSEMBLY RHTEPE-12-E BUSH INSTALLATION TOOL BAS-19 FASTENER INSTALLATION TOOL ø 7/8 OK NO Check hole diameter using CAL Assemble the bush and OG13.2 plunger to RHTEPE-12-E bush installation tool CAL BUSH OG 13.2 RHTEPE-12-E Insert bush into hole and operate tool to install bush INSTALLED BUSH Assemble terminal lug, locking washer, expansion bolt and M12 NUT against bush flange. Secure BAS-19 to threaded end of expansion bolt. EXPANSION BOLT M12 NUT TERMINAL LUG LOCKING WASHER BAS-19 BAS-19 T [Nm] T Tighten BAS-19 to push thrust pin through expansion bolt. D Cu Al M

9 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. Schematic view of the extrusion process (section) Extensive testing, performed in the test laboratory and in the field, have demonstrated a low and constant resistance, mechanical stability and protection from atmospheric corrosion. Examples of the electrical tests Heat Cycling Tests Short Circuit Testing On site testing Examples of tests in salt water environments Salt Mist Exposure Testing 10

10 TYPICAL APPLICATIONS AR60D installation Transmission of coded and return current on lines fitted with automatic block Signalling and traction current connection to manganese steel cast exchange units Protection equipment Various connections involved in the train location system Return current connections to substations Connections of metallic structures to rails for grounding purpose Electrical connection of underground metal structures to rails Examples of lines equipped with automatic block. Examples of AR60D system in electric joint applications. Features, and advantages of this system are explained in various railways magazines The AR60D system is used world wide proving to be fully reliable in all the working conditions. 11

11 ELECTRICAL CONNECTION SYSTEMS TO RAILS AND TO TRACK EQUIPMENT 1 1) Example of electrical connections using a low stranded conductor to provide electrical continuity on cast manganese steel crossovers. 1a) AR60D rail web connection, rail side 2) Example of electrical connections using a flexible cable to provide electrical continuity on cast manganese steel crossovers. 2a) AR60D rail web connection, rail side 3) AR260D double contact rail web connection 1a 2 2a 3 12

12 HYDRAULIC SYSTEMS FOR RAIL WEB ELECTRICAL CONNECTIONS AR., TYPE HTEPE-DETY Hand 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 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 Dimensions: Pump body: length 10.8 in. width 5.12 in. Head: length 4.5 in. Total weight: 7.7 lbs RHTEP System consisting of: a - Hydraulic head type RHTEP-S to be connected to a pump developing 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 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 Dimensions: length: Weight: 4.17 in lbs KIT AR 69-INST Including: CAL Gauge M9 M5 Adapter OG 6.5 Plunger For the installation of the electrical contact AR 69D type EXTRACTOR TO REMOVE AR 60-1 BUSHES FROM THE RAILS ECR19+ECR1 Kits In order to remove AR60D bushes from the rail, available (upon request) is the ECR 19 kit (punch + puller) with the positioner ECR-1. For use please refer to the following picture MECHANICAL HAND SETTING TOOL FOR AR69D MTE-1 The MTE1 hand setting tool provides an easy and quick mechanical installation. The tool comes complete with: - 2 plungers 0G 6.5 type in special Steel (for extruding AR69D bonds) - CAL gauge for both check of the rail hole and for screwing of the plunger itself into the head - Canvas bag - Weight: 3 lbs 13

13 TEMPORARY RAIL ELECTRICAL CONNECTION SYSTEM TEMPORAIL FOR RETURN CURRENT, SIGNALLING AND EARTHING APPLICATIONS TEMPORAIL The 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 Temporail 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 systems 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 New Typical installation of Cembre Temporail Temporail kit code Comprising RTC1Al * 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 preparation to ensure good electrical connection as the clamp deeply scores the surface of the rail foot during installation. ATENTED PPATENTED Extraction Insertion Simple, safe insertion and extraction of Cembre Temporail 14

14 RAIL DRILLS 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. LD-1PY-ECO - 2 cycle gas D NT TE E NT TE E GENERAL 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 P Drilling range: Ø 9/32" to 1 9/16" D A Max drilling thickness: 2 3/4 Weight: 41.5 lbs PA According to phase 2 European Directives LD-2EY - Electric D NT TE E P D A NT TE E PA GENERAL 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 15

15 RAIL DRILLS GENERAL FEATURES: Engine: hydraulic Oil input flow: 5 gpm Oil input pressure: 2,000 psi Power: 2 kw Weight: 44 lbs D LD-8H - Hydraulic NT TE E NT TE E P D A PA Drilling range: Ø 9/32 to 1 1/2 NT TE E PA According to phase 2 European Directives and EPA regulations Drilling range: Ø 9/32 to 1 1/2 NT TE E D PA GENERAL FEATURES: Direct current electric motor Supply voltage: 24 V DC Power rating: 345 W Weight: 37 lbs P D A BATTERY PACK 24 V DC 16 Ah NT TE E LD-12BY - Battery D GENERAL 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 NT TE E P D A LD-41PY - Four cycle gas Drilling range: Ø 9/32 to 3/4 BATTERY PACK: BP (24 V DC 16 Ah): 33.2 lbs. BP (24 V DC 10 Ah): 24.2 lbs. Battery condition display Protection fuse Battery charger 24V 2A max. BATTERY PACK 24 V DC 10 Ah 16

16 RAIL DRILLS Typical fixing situations: To the Railweb This system is ideally suited to working when the track is under possession or if not under possession 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. Rail drills for drilling in correspondence of guard rail LD-1PYGR-ECO GENERAL 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-2EYGR GENERAL 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-41PYGR GENERAL 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 17

17 STANDARD ACCESSORIES (ALWAYS SUPPLIED WITH THE DRILLING MACHINE) RAIL DRILLS TYPE LD-1PY-ECO AND LD-2EY These machines are supplied with the following accessories: DBG-Y Over Rail Clamp For clamping of drilling machine to rail web and track fittings Complete with TDB 6 termination * SR 5000 Coolant unit Coolant 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. Measure for mixture preparation* ( ) It allows to prepare the oil-gas mixture Oil for the gear box for LD-3PY 100 ml ( ) Oil for the gear box for LD-2EY 140 ml ( ) * Range of tools 1 x spark plug key* 1 x 5 mm Allen key ( ) 1 x 6 mm Allen key ( ) 1 x 4 mm Allen key, with handle ( ) 1 x swarf brush ( ) * Accessory supplied only for LD-1PY-ECO ( ) and LD-41PY ( ) rail drills Socket head cap screws 4 pcs for clamping cutter or adaptor into spindle shaft ( ) 4 pcs for securing drilling template to the front plate ( ) 4 pcs for securing heavy duty drilling template to the front plate ( ) ARE Adaptor For the external application of the coolant. Fits directly to the SR 5000 coolant unit coupler FOR USE WITH BROACH CUTTERS 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) FOR USE WITH SPIRAL BITS DPE Spacer For use with APE adaptor to activate the coolant when using spiral drill bits. 18

18 OPTIONAL ACCESSORIES FOR RAIL DRILLING MACHINES (TO BE ORDERED SEPARATELY) 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) VAL P24-CS VAL P24 with wheels and folding handle. 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 OPTI-2 engine lubricant One mix for all 2 cycle engines 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). 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) 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. 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 19

19 OPTIONAL ACCESSORIES FOR RAIL DRILLING MACHINES (TO BE ORDERED SEPARATELY) Rail shoes for positioning the drill on running and guard rails Enable 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. Cembre Rail Shoes Drilling On Running Rails MPAU MPAU-10 MPAF 40 LB ASCE MPAF 60 LB ASCE MPAF 80 LB ASCE MPAF 85 LB ASCE MPAF 85 LB PRR MPAF 85 LB PS MPAF 90 LB ARA-A MPAF 90 LB ASCE MPAF 100 LB ARA-A MPAF 100 LB ARA-B MPAF 100 LB ASCE MPAF 100 LB DY MPAF 100 LB NH MPAF 100 LB RE MPAF 100 LB RE-HF MPAF 100 LB PRR Cembre universal rail shoe (for other types of rail or special application such as drilling #20 high speed switch points) Cembre universal short rail shoe (for other types of rail or special application) Cembre Shoe for drilling 40 LB ASCE rail (Bolt hole elevation 1 9/16 ) Cembre Shoe for drilling 60 LB ASCE rail (Bolt hole elevation 1 115/128 ) Cembre Shoe for drilling 80 LB ASCE rail (Bolt hole elevation 2 3/16 ) Cembre Shoe for drilling 85 LB ASCE rail (Bolt hole elevation 2 17/64 ) Cembre Shoe for drilling 85 LB PRR rail (Bolt hole elevation 2 1/16 ) Cembre Shoe for drilling 85 LB PS rail (Bolt hole elevation 2 15/64 ) Cembre Shoe for drilling 90 LB ARA-A rail (Bolt hole elevation 2 9/16 ) Cembre Shoe for drilling 90 LB ASCE rail (Bolt hole elevation 2 45/128 ) Cembre Shoe for drilling 100 LB ARA-A rail (Bolt hole elevation 2 3/4 ) Cembre Shoe for drilling 100 LB ARA-B rail (Bolt hole elevation 2 65/128 ) Cembre Shoe for drilling 100 LB ASCE rail (Bolt hole elevation 2 65/128 ) Cembre Shoe for drilling 100 LB DY rail (Bolt hole elevation 2 5/8 ) Cembre Shoe for drilling 100 LB NYNH& H rail (Bolt hole elevation 2 39/64 ) Cembre Shoe for drilling 100 LB RE rail (Bolt hole elevation 2 45/64 ) Cembre Shoe for drilling 100 LB RE-HF rail (Bolt hole elevation 2 45/64 ) Cembre Shoe for drilling 100 LB PRR rail (Bolt hole elevation 2 9/32 ) MPAF 100 LB PS MPAF 105 LB DY MPAF 115/119 LB RE MPAF 122 CB MPAF 127 LB DYM MPAF 130 LB RE MPAF 130 LB RE-HF MPAF 130 LB RE-HFB MPAF 130 LB PS MPAF 131 LB RE MPAF 132 LB RE MPAF 133 LB RE MPAF 136 LB RE MPAF 136 LB LVM MPAF 140 LB RE MPAF 141 LB AB MPAF 152 LB PS MPAF 155 LB PS Cembre Shoe for drilling 100 LB PS rail (Bolt hole elevation 2 31/64 ) Cembre Shoe for drilling 105 LB DY & 110 LB RE rail (Bolt hole elevation 2 43/64 ) Cembre Shoe for drilling 112/115/119 LB RE rail (Bolt hole elevation 2 7/8 ) Cembre Shoe for drilling 122 CB rail (Bolt hole elevation 2 7/8 ) Cembre Shoe for drilling 127 LB DY rail (Bolt hole elevation 3 1/8 ) Cembre Shoe for drilling 130 LB RE/HF-A rail (Bolt hole elevation 2 3/4 ) Cembre Shoe for drilling 130 LB RE/HF rail (Bolt hole elevation 3 1/16 ) Cembre Shoe for drilling 130 LB HF-B rail (Bolt hole elevation 3 3/8 ) Cembre Shoe for drilling 130 LB PS rail (Bolt hole elevation 2 3/4 ) Cembre Shoe for drilling 131 LB RE rail (Bolt hole elevation 3 1/2 ) Cembre Shoe for drilling 132 LB RE running rail (Bolt hole elevation 3 3/32 ) Cembre Shoe for drilling 133 LB RE rail (Bolt hole elevation 3 ) Cembre Shoe for drilling 136 LB RE rail (Bolt hole elevation 3 3/32 ) Cembre Shoe for drilling 136 LB LE VAL rail (Bolt hole elevation 3 1/16 ) Cembre Shoe for drilling 140 LB RE and 140 PS rail (Bolt hole elevation 3 ) Cembre Shoe for drilling 141 LB AB and 141 LB RE rail (Bolt hole elevation 3 3/32 ) 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) 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) 20

20 OPTIONAL ACCESSORIES FOR RAIL DRILLING MACHINES (TO BE ORDERED SEPARATELY) Cembre Rail Shoes Drilling On Guard Rails (Using DBG-GR clamp) Cembre Rail Shoes Drilling On Crane Rails (using DBG-AY and 2 depth cutter with PPL2) 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 ) MPAF-175LB-258 MPAF-171LB-258 MPAF-104LB-2716 MPAF-105LB MPAF-135LB Cembre Shoe for drilling 175 LB rail (Bolt hole elevation 2 5/8) Cembre Shoe for drilling 171 LB rail (Bolt hole elevation 2 5/8) Cembre Shoe for drilling 104 LB rail (Bolt hole elevation 2 7/16) Cembre Shoe for drilling 105 LB rail (Bolt hole elevation 2 13/64) Cembre Shoe for drilling 135 LB rail (Bolt hole elevation 2 15/32) Cembre Rail Shoes Drilling On Girder Rails (Using DBG-LY clamp and 2 depth cutters) Cembre Rail Shoes Drilling On Aluminum Composite Rails (using DBG-LY and 2" depth spiral bits) MPAF 128/149 LB GR MPAF 128/149 LB-GR/1 MPAF 149 LB GR 234 MPAF GGR 118 MPAF RI 60 N MPAF R MPAF NP4AM MPAF BA9101 MPAF TR68 Cembre Shoe for drilling girder rail (Bolt hole elevation 3 ) Cembre Shoe for drilling girder rail (Bolt hole elevation 2 3/4") Cembre Shoe for drilling girder rail (Bolt hole elevation 2 3/4 ) Cembre Shoe for drilling girder rail (Bolt hole elevation 2 3/8 ) Cembre Shoe for drilling girder rail (Bolt hole elevation 2 7/8 ) Cembre Shoe for drilling girder rail Cembre Shoe for drilling girder rail (Bolt hole elevation 2 7/8 ) Cembre Shoe for drilling LB girder rail (Bolt hole elevation 2 7/8 ) Cembre Shoe for drilling girder rail (Bolt hole elevation 3 3/32") 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) VERTICAL POSITIONING TEMPLATE MPAS RI 60 N MPAS 35G-GP Cembre Shoe for drilling vertically in the groove of girder rail type RI60N (see picture A) Cembre Shoe for drilling vertically in the groove of girder rails type 35G and 35GP (see picture A) Picture A 21

21 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) 22

22 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 centre 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 TDB6/100RE 100 ASCE SRT100 ASCE TDB6/100ASCE 105 DY SRT105 DY TDB6/105DY 112 RE SRT112 RE TDB6/112RE 115 RE SRT115 RE-86.5 TDB6/115RE 119 RE SRT119 RE TDB6/119RE 127 DY SRT127 DY TDB6/127DY 132 RE SRT132 RE-86,5 TDB6/132RE 133 RE SRT133 RE TDB6/133RE 136 RE SRT136 RE TDB6/136RE 140 RE SRT140 RE TDB6/140RE 141 AB SRT141AB-86,5 TDB6/141AB 23

23 OPTIONAL ACCESSORIES FOR RAIL DRILLING MACHINES (TO BE ORDERED SEPARATELY) 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 RE MRFY 11: Suitable for drilling the following rails 100 ARA-B and 105 DL&W MRFY 12: Suitable for drilling the following rails 115, 119, 132, 136, 140 LB RE, 130 and 155 PS MRFY 13: Suitable for drilling the following rails 80, 90 LB ASCE and 100 ARA-A MRFY 14: Suitable for drilling the 85 LB ASCE rail MRFY 15: Suitable for drilling 130 LB RE and 136 LB LE. VAL rails MRFUY: Universal positioning gauge for all rail sizes MRFY 16C: For Canadian market MRF SR-SFA Please note: other positioning gauge sizes available upon request. SR-SKI Support MRF SR-SF POSITIONING JIG MRF SR-SFA and MRF SR-SF MRF SR-SFA The 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-SF The MRF SR-SF 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. SR... Templates KIT 24

24 OPTIONAL ACCESSORIES FOR RAIL DRILLING MACHINES (TO BE ORDERED SEPARATELY) BROACH CUTTERS These cutters rapidly produce high quality, accurate holes in a single pass. The automatic lubrocooling system reduces friction and eliminates heat build up during the drilling operation. Under standard conditions a broach cutter can drill holes, depending on the hardness of the rail. 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 (to be used with 3 long cutters) Cembre Broach Cutters 2 Depth of Cut (To Be Used With Cembre PPL2 Pilot Bit) (7/8" hole diameter) (15/16 hole diameter) (1 hole diameter) (1 1/16" hole diameter) (1 1/8" hole diameter) (1 3/16 hole diameter) (1 1/4" hole diameter) (1 5/16 hole diameter) (1 3/8" hole diameter) (1 7/16" hole diameter) (1 1/2" hole diameter) 12218* (9/16" hole diameter) Cembre Broach Cutters 7/8 Depth of Cut (To Be Used With Cembre PPC2 Pilot Bit) (7/8" hole diameter) (15/16" hole diameter) (1" hole diameter) (1 1/16" hole diameter) Cembre TSC 1 1/8" (1 1/8" hole diameter) (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) (1 3/8" hole diameter) (1 7/16" hole diameter) Cembre TSC 1 1/2" (1 1/2" hole diameter) Cembre TSC 3/4" (3/4" hole diameter) Cembre Broach Cutters 3 Depth of Cut (To Be Used With Pilot Bit) (3/4" hole diameter) (13/16" hole diameter) (7/8" hole diameter) (15/16" hole diameter) (1" hole diameter) (1 1/8" hole diameter) Cembre HEN Carbide Cutters 7/8 Depth of Cut CCQ 3/4-7/8 CCQ 7/8-7/8 CCQ 1-7/8 CCQ 1 1/8-7/8 CCQ 1 3/16-7/8 CCQ 1 1/4-7/8 CCQ 1 5/16-7/8 CCQ 1 1/2-7/8 Cembre HEN Carbide Cutters 2 Depth of Cut CCQ 1-2 CCQ 1 1/2-2 Cembre HEN Carbide Cutters 3 Depth of Cut CCQ 7/8-3 (3/4" hole diameter) (7/8" hole diameter) (1" hole diameter) (1 1/8" hole diameter) (1 3/16" hole diameter) (1 1/4" hole diameter) (1 5/16" hole diameter) (1 1/2" hole diameter) (1" hole diameter) (1 1/2" hole diameter) (7/8" hole diameter) 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. Other sizes available on request AOT adapter requires the PPL2 Pilot Bit. TWIST PUSH *special pilot bit required 25

25 OPTIONAL ACCESSORIES FOR RAIL DRILLING MACHINES (TO BE ORDERED SEPARATELY) 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 holes, depending on the hardness of the rail. SPECIAL APPLICATION FOR CEMBRE RAIL DRILLS Application Clamp Template Cutters Extension Pilot Bit UIC 69* DBC AAT (7/8" hole diameter) (15/16 hole diameter) (1 hole diameter) (1 1/16" hole diameter) (1 1/8" hole diameter) (1 3/16 hole diameter) (1 1/4" hole diameter) (1 5/16 hole diameter) (1 3/8" hole diameter) (1 7/16" hole diameter) (1 1/2" hole diameter) (9/16" hole diameter) PFA PPL4 150 LB TST 50 + DBG-AY MPAF 150 LB-3Y (3/4" hole diameter) (13/16" hole diameter) (7/8" hole diameter) (15/16" hole diameter) (1" hole diameter) (1 1/8" hole diameter) PFA 1 PPDF2 Aluminum-Rail- Aluminum COMPOSITE TST 50 + DBG-AY MPAF 56 CF COMP 1 MPAF 84 CF COMP 2 MPAF 84 CP COMP 3 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) - - * = APPLICATION DEVELOPED FOR NARROW CHAIRS 1 = FOR DRILLING 56 lb ALUMINUM BAR MANUFACTURED BY FOSTER 2 = FOR DRILLING 84 lb ALUMINUM BAR MANUFACTURED BY FOSTER 3 = FOR DRILLING 84 lb ALUMINUM BAR MANUFACTURED BY PORTER 26

26 EXAMPLE OF RAIL DRILLING MACHINE INSTALLATION USE ON RUNNING RAILS STANDARD USE DBG-Y over rail clamp equipped with TDB- 6 termination DRILLING BY THE GUARD RAIL DBG-GR over rail clamp equipped with TDB-1 termination USE ON GIRDER RAIL (for example 128 or GGR 118) 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 27

27 AUTOMATIC RAIL DISC SAW ROBOKATTA RDS-14P-AA presents 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: Physical Effort: Harmful Dust: Sparks: Exhaust Fumes: Acoustic Noise: Zero Zero Zero Zero Zero 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 fundamental 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. 28

28 AUTOMATIC RAIL DISC SAW NDING Technical characteristics: EPATENT P 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 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 Auxillary switching device Optional accessories: VAL RDS case for storage of the RDS-14P rail saw. RDS-14P rail disc saw VAL AA-RDS case for storage of the AA-RDS automatic support arm. SSR1 stabiliser support for short rail lengths. May be blocked in Hold position to simplify rail saw location and start-up operations Can be switched to manual mode. 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 ) Consult us for ROBOKATTA version equipped with 7/8 diameter disc support shaft SA-RDS manual support arm Support arm for using ROBOKATTA in manual mode only. Expert operator cutting times and accuracy in automatic and manual modes 29

29 PATENTED PATENTED SUPPORT TROLLEY CS-SD CS-SD-TA The 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. The trolley is easily assembled and can comfortably be carried by a single operator. General features: Weight: (without connecting rod) 38.5 lbs Connecting rod weight: 26.4 lbs Dimensions (in.): Portable drilling machines for wood ties SD-15PR-ECO + support trolley CS-SD Portable gas engine impact wrench NR-11P + support trolley CS-SD 30

30 SUPPORT TROLLEY ACCESSORIES POSSIBILITY OF EMPLOYMENT OF PORTABLES IMPACT WRENCH NR-11P AND DRILLING MACHINE FOR WOOD TIES SD-15PR-ECO WITH SUPPORT TROLLEY CS-SD IN VERTICAL KCS-NR interface kit for vertical use with support trolley CS-SD IN HORIZONTAL KHOR-NR interface kit for horizontal use with support trolley CS-SD IN BRIDGES IN ROAD CROSSINGS 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. KLE-32-CS KLE-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 side Short one up to 32 from field side KCS-SD-RC Interface kit specifically designed for road crossing applications to be installed on existing support trolley CS-SD. 31

31 PATENTED PATENTED PORTABLE - TWO CYCLE GAS ENGINE IMPACT WRENCH NR-11P HIGH TORQUE 1844 ft. lbs NR-11P Ideal for Railways, Construction sites, Oil and Mining Industries, Shipyards. Protective shield To protect tank and engine from accidental shocks General features: Torque selector With 5 positions - Fuel Tank This 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. - Handlebar Careful 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. - Control handle Control 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 acceleration, 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 accordance 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. Forward/Reverse selector Smooth change - 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 handarm vibration felt by operators. - Easy-start With its decompression button, primer and digital ignition coil, minimum time and effort are required to start NR11P. 32

32 NR-13E-110 Technical Features: Engine: single phase electric motor Supply voltage: V / 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) PORTABLE ELECTRIC IMPACT WRENCH NR-13E-110 HIGH TORQUE 1844 ft. lbs PATENTED PATENTED Fitted with PRCD device (Portable Residual Current Device) ACOUSTIC NOISE (Directive 2006/42/EC, annexe 1, point letter u) Protection of workers against risks of exposure to noise during work. NR-11P PROTECTION AND SAFETY AT WORK OF IMPACT WRENCHS The weighted continuous acoustic pressure level equivalent A at the work place L pa is equal to... 96,2 db (A) The maximum value of the weighted acoustic displacement pressure C at the work place L pcpeak is equal to ,9 db (C) The acoustic power level emitted by the machine L WA is equal to ,9 db (A) NR-13E-110 The weighted continuous acoustic pressure level equivalent A at the work place L pa is equal to... 98,4 db (A) The maximum value of the weighted acoustic displacement pressure C at the work place L pcpeak is equal to ,6 db (C) The acoustic power level emitted by the machine L WA is equal to ,2 db (A) RISK DUE TO VIBRATION (Directive 2006/42/EC, annexe 1, point ). Tests carried out in compliance with the indications contained in UNI ENV and UNI EN part 1 st 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-11P 8,68 m/sec 2 max NR-13E m/sec 2 max 33

33 PORTABLE - TWO CYCLE GAS ENGINE IMPACT WRENCH NR-11P MAIN SPECIFICATION ENGINE Type: Two cycle, forced-air cooled, single cylinder Displacement: 55 cc Fuel tank capacity: 0.3 USA Gal Synthetic oil 1:50 Fuel mixture ratio: { 2 cycle mineral oil 1:25 Revolution (idle): 2800 rpm ± 200 Revolution (loaded, impact): 7000 rpm Revolution (non loaded, max): 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

34 PORTABLE - TWO CYCLE GAS ENGINE IMPACT WRENCH NR-11P OPTIONAL ACCESSORIES: Ref. XT 100 SJ 1 CLIP NR KCS-NR KHOR-NR KEB-NR CS-SD VAL P20 VAL NR TARPCOVER 027-NR 1 x 4 (length) extension 1 swivel joint Description Retaining circlip for fastening sockets to the mandrel. Kit for mounting NR11-P to CS-SD support trolley. interface kit for horizontal use with support trolley CS-SD extension kit designed for road crossings applications. Support trolley common to NR11-P and sleeper drilling machines SD-15PR-ECO and SD-10E-110. Plastic box for storage of sockets and accessories. Steel case for storage of NR11-P and VALP20 accessories box. 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 Retaining circlip for fastening sockets to the mandrel having an external diameter range: pieces supplied as standard. CLIP-NR 57 Retaining circlip for fastening sockets to the mandrel having an external diameter range: piece supplied as standard. TARPCOVER 027-NR VAL P20 VAL NR MAIN APPLICATIONS: Assembly of steel structures such as bridges, building frames, rail tracks, ship building, heavy equipment maintenance, pipelines and industrial applications. Anti-vibration couplings reduce transmission of vibration to the operator. The protective handlebar structure facilitates a comfortable dorso-lumbar operating position without wrist injury. A reduced mandrel axis to machine base dimension facilitates a more convenient horizontal position for working with track bolts, even when operating across sleepers. 35

35 PORTABLE TWO CYCLE GAS TIE DRILL WITH FORWARD AND REVERSE FEATURE New PA PA According to phase 2 European Directives D NTE TE NT TE E D., " # $ / & - TWO CYCLE GAS ENGINE SD-15PR-ECO ' 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 0 ) * * Depending on the type of wood it is also possible to drill larger holes +! - Accelerator Accelerator lever fitted with safety switch to prevent accidental operation. " - Centrifugal clutch n co t # - Operating handle for o ming Fitted 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. c $ - Emergency lever to EN13977 g on for min Handle will rotate through 90 for operator comfort. Emergency lever for the immediate release of the drill bit. % - Shock absorbers Shock absorbers fitted between the drive shaft and spindle, reduce the transmission of machine vibrations to the operator. * - Safety guard & - Carrying handle (see page 39) Carrying handle; also used for locating the drilling machine into the CS-SD trolley. 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 completion of the drilling operation, thereby minimising operator effort. ' - Depth gauge + - Guard nozzle Depth Gauge; easy to operate using the graduated scale, for adjusting the depth of drilled hole. Interchangeable, Guard Nozzle TPM200-26, for locating into chairs and base plates, as commonly used on existing tracks. ( - MND spindle, - Engine MND spindle, for automatically securing drill bits, with a 0.55 in. (14 mm) diameter shank. New engine conforming to phase 2 of 97/68/CE, 2001/63/CE and 2002/88/ CE directives. ) - 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. - - Forward/Reverse selector Reverse action enables easy withdrawal of auger. 36

36 PATENTED PATENTED PORTABLE DRILLING MACHINES FOR WOOD TIES TYPES SD-15PR-ECO AND SD-10E-110 ELECTRIC SD-10E-110 General features: Engine: single phase electric motor Supply voltage: V / 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 The SD-10E-110 is suitable for use with the CS-SD support trolley (see pages 30-31) EN13977 confo r m in g to conforming to PROTECTION AND SAFETY AT WORK OF DRILLING MACHINES ACOUSTIC NOISE (Directive 2006/42/EC, annexe 1, point 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 L pa is equal to... 97,9 db (A) The maximum value of the weighted acoustic displacement pressure C at the work place L pcpeak is equal to ,9 db (C) The acoustic power level emitted by the machine L WA is equal to ,5 db (A) SD-10E-110 The weighted continuous acoustic pressure level equivalent A at the work place L pa is equal to... 93,1 db (A) The maximum value of the weighted acoustic displacement pressure C at the work place L pcpeak is equal to db (C) The acoustic power level emitted by the machine L WA is equal to ,3 db (A) RISK DUE TO VIBRATION (Directive 2006/42/EC, annexe 1, point ). Tests carried out in compliance with the indications contained in UNI ENV and UNI EN part 1 st 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-ECO 7,06 m/sec 2 max SD-10E-110 3,7 m/sec 2 max 37

37 PORTABLE DRILLING MACHINES FOR WOOD TIES TYPES SD-15PR-ECO AND SD-10E-110 OPTIONAL ACCESSORIES FOR WOOD TIES DRILLING MACHINES Augers for Cembre tie drills Cembre Type Diameter In. (mm) Lenght In. (mm) PV 7/16" 7/16" (11) PV 140 9/16" (14) PV 160 5/8" (16) PV /64" (17) PV /16" (18) PV 190 3/4" (19) 12.8 (325) PV /32" (20) PV /16" (20) PV 220 7/8" (22) PV 170/220 43/64" (17) - 7/8" (22) GUARD NOZZLE TPM... Standard Optionals (available on request) Contac Cembre for different applications, or for drilling operations, where an alternative size, end piece is required. TPM TPM TPM TPM TPM... Guard Nozzle for the moveable guard, interchangeable with the standard nozzle. TPM... 5/8 ADAPTER key 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 5/8 Adapter VAL P 6 Plastic case for storing the drill bits and standard accessories supplied with the machine. This case can be stored inside the drilling machine case. VAL SD Robust steel case for storing the drilling machine and VAL P6 accessory case. Carbide Counter Bit 1 1/2" (to be used with PV180) TARPCOVER 026-SD Protection cover manufactured in Polyethylene HDPE and UV resistant. Temperature range: -40 C to +70 C. TARPCOVER 026-SD VAL P6 VAL SD 38

38 PORTABLE DRILLING MACHINES FOR WOOD TIES TYPES SD-15PR-ECO AND SD-10E-110 Two stroke petrol engine machine, purpose built for use with the support trolley CS-SD Easily combined with Support Tolley CS-SD 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. Example of use on double crossovers. The SD-15PR-ECO unit enables 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 easily be removed from the track. The unit is easily assembled and can comfortably be carried by a single operator. 39

39 PANDROL E CLIP MACHINE "E" Clip Applications on both Wooden and Concrete Ties. PCM-2P/U PCM-2P/U1 PCM-2P For e type PANDROL CLIPS Rapid performance with a high degree 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. Braking system PCM-2P-BRAKED meets the requirements of EN Easily adjustable to work both on wooden and concrete ties (long and short baseplate version) on several rail types. PCM-2P/U PCM-2P PCM-2P/U1 Typical application on which the PCM-2P/U is used: long baseplate (7.87 in.) on wooden ties. 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. Typical application for the PCM-2P/U1: special metro baseplate on concrete ties or basement. 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. Inserction and extraction of the clip by means of the PCM-2P/U1 40

40 PANDROL E CLIP MACHINE GENERAL FEATURES The PCM-2P/U... machine from Cembre is suitable for the insertion and The pump unit is suited by a sturdy and powerful 4-stroke engine, extraction of e type pandrol clips used with 2.76 in. & 7.87 in. bases; Honda or equivalent, with noise levels according to CARB-EPA The unit is immediately ready to use requiring no assembly or disasstandards. sembly of accessories; Does not interfere with rail circuits due to the three insulated wheels; Particularly suited to rail adjustment work, for instance on in-progress Compactness and easy transport makes the PCM-2P/U... machine rail sections or track renewal, the PCM-2P/U... & PCM/2P machines a very reliable for the immediate use. also generally applicable in maintenance operations. Weight: Pump unit 108 lbs, Clamp unit 106 lbs, trolley unit 20 lbs, Ballast on ties does not unduly affect the machine, as the clamp do wheel bar 11 lbs not rest on them; The self-braking system is quick & easy to connect and intervenes The pump unit is the same as that used on PCM-2P/U, PCM-2P/U1, automatically when the operator releases the handle of the machine. PCM-2P/FC and PCM-2P guaranteeing and high versatility in case of several applications. ASSEMBLY SEQUENCE PCM-2P/U.. 4 3rd wheel bar PUMP UNIT 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. 2 direction of operation TROLLEY UNIT 1 CLAMP UNIT 3 3rd WHEEL BAR PCM-2P PCM-2P specific just for 2.76 in. bases on concrete ties. Easy assembly and transportation by two persons

41 PANDROL FAST CLIP MACHINE 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. Braking system Pandrol "Fast Clips" machine meets the requirements of EN PARKED POSITION SHOULDER TOE INSULATOR FASTCLIP POSITIVE LOCK-IN INSTALLED POSITION 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. INSULATOR CHANGING POSITION GENERAL FEATURES 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 disassembly 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 extracted 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. Extraction and insertion of Pandrol fast clips. 42

42 PANDROL FAST CLIP MACHINE ASSEMBLY SEQUENCE 4 PUMP UNIT direction of operati on 2 5 TROLLEY UNIT 6 3 3rd WHEEL BAR 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 CLAMP UNIT OPTIONAL ACCESSORIES FOR PANDROL CLIP MACHINES TARPCOVER 019-PCM MPC 6 Robust UV resistant cover for PCM machines. Temperature range: -40 C to +70 C. Manometer for checking the operation of the maximum pressure value in the hydraulic circuit. 43

43 EPATENT P CONNECTING JOINTS FOR PROFILED CONTACT WIRES The joint allows connection between new or new and worn contact wires without any tapering operation, assuring a uniform and continuous sliding area of the pantograph; the use of these joints also reduces intervention 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). Suitable for 4/0 AWG contact wire CONNECTING JOINT TYPE FTGW 100 TORQUE RATIO Nm GROOVED CONTACT WIRE Section (mm 2 ) Ø (mm) REFERENCE STANDARD ,0 FTGW , ,2 FTGW ,5 EN (Type AC-120 or Cu and CuAg 0,1) 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: NDING HYDRAULIC CUTTING HEAD RH-TFC Contact wire cut with a traditional cutter Hydraulic RH-TFC head with interchangeable dies to perform a perfectly perpendicular cut without deformation of the wire shape (see page 45 for the selection of the available tools). Contact wire cut with the RH-TFC hydraulic head 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 operated PO-7000, foot operated B70M-P24A portable electro-hydraulic 24V DC motor driven, powered by internal battery or external supply. DIE SETS A wide range of dies is available to cut most profiled contact wires or stranded conductors. MFC cutting die sets available Contact Wire Type Cutting Dies Cu/Steel conductor MFC-D7.5-S Cu or Al Round rod Ø 10.8 MFC-D10.8 Cu or Al Round rod Ø 14.5 MFC-D14.5 Cu or Al Round rod Ø 16.1 MFC-D16.1 2/0 AWG MFC - 2/0 AWG 4/0 AWG Grooved MFC - 4/0 AWG 300 MCM Grooved MFC MCM 335 MCM Grooved MFC MCM 350 MCM Grooved MFC MCM For further information contact the local Cembre office. 44

44 HYDRAULIC CUTTING TOOLS TYPE RH-TFC, HT-TFC, B35-TFC FOR PROFILED CONTACT WIRE RH-TFC Hydraulic presshead complete with quick automatic coupler for connection to a hydraulic pump with a max working pressure of 10,000 psi. Suitable for cutting profiled contact wires, on electrified traction systems. Cutting capacity (diameter max.): Max operating pressure: Dimensions: length width Weight 0.79 in. 10,000 psi 7.72 in in lbs Simple 3 stage operation 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 VAL P15 Supplied 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 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. 3 Cutting capacity (diameter max.): Max operating pressure: Dimensions: length width Weight 0.79 in. 8,600 psi 14.7 in in lbs B 35M-TFC The 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 remaining 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 ( V) included. Operating temperature: +5 to +122 F VAL P17 Supplied in a robust plastic case VAL P17 suitable for storage of the tool and 4 sets of dies. - Dimensions 18.5 x 15.1 x 4.3 in. - weight 4.4 lbs New Available upon request: CINV IC, 12V car power inverter (see page 50) NEW 18V Li-Ion B A T T E R Y Cutting capacity (diameter max.): Max operating pressure: Dimensions: length width height Weight 0.79 in. 6,500 psi 15.2 in. 7.7 in. 5.2 in. 7.5 lbs VAL P43 Supplied in a robust plastic case VAL P43 suitable for storage of the tool and 3 sets of dies. - Dimensions 19.8 x 15.0 x 5.4 in. - weight 5.7 lbs 45

45 GROOVED CONTACT WIRE ALIGNMENT DEVICE DURING THE INSTALLATION OF CONNECTING JOINTS AD-GW This 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 selfgripping clamps and a Tirfor type mechanical ratchet block commonly used for tensioning contact wire in jointing operations. HC-GW AD-GW Guide wheels Grooved contact wire AD-GWL suitable to install long type contact wire joints having a maximum length of in. The maximum tension weight admitted is lbf. AD-GWL Contact wire to be retained Cutting point New contact wire SELF-GRIPPING CLAMP SELF-GRIPPING CLAMP Hook Hook TIRFOR Contact wire to replace 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. 46

46 MECHANICAL STRAIGHTENING DEVICE FOR GROOVED CONTACT WIRES MSGW The 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-E1 For trolley wire 350MCM and larger General features: Dimensions inches: 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 DIES 4/0 AWG Grooved MSGW 110CN-4/0AWG-3D 2/0 AWG Grooved MSGW 2/0AWG-3D 335 MCM Grooved MSGW 335MCM-3D 350 MCM Grooved MSGW 350MCM-3D 47

47 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 HYDRAULIC NUT SPLITTING HEAD SINGLE BLADE HEADS & BATTERY OPERATED UNIT RHTD 3241 Application field: suitable for splitting nuts from 1-1/16" (M 18) to 1-5/8" (M 27) hexagon Working pressure: 10,000 psi Weight: 10.1 lbs RHTD 1724 Application field: suitable for splitting nuts from 5/8" (M 10) to 1-1/16" (M 18) hexagon Working pressure: 10,000 psi Weight: 3.9 lbs VAL P4 RHTD1724, RHTD3241 are supplied in a sturdy plastic case suitable for storing the tool and accessories B-TD1724A 14.4 V battery operated hydraulic tool suitable for splitting fastening bushes, hexagonal and square nuts as per RHTD

48 HYDRAULIC NUT SPLITTING HEAD DOUBLE BLADE HEAD & BATTERY OPERATED UNIT Requires connection to a pump developing 10,000 psi pressure. Lightweight and handy; its shape and dimensions have been designed for the best comfort of operation in a variety of applications. The blades can be easily replaced in case of damage. Supplied in a sturdy plastic case suitable for storing the tool and accessories. RHTD 3241T Application field: Suitable for splitting square and hexagonal nuts or fastening bushes as indicated in the table below Working pressure: Weight: 10,000 psi 10.8 lbs VAL P4 RHTD3241T is supplied in a sturdy plastic case suitable for storing the tool and accessories B-TD3241TA 14.4 V battery operated hydraulic tool suitable for splitting fastening bushes, hexagonal and square nuts as per RHTD 3241T. 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" 49