Cembre RDS-14P, RDS-14P.78 Operation And Maintenance Manual

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14 M 113 E

ENGLISH

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DĂŶĂŐĞŵĞŶƚ^ǇƐƚĞŵ

RAIL SAW

RDS-14P RDS-14P.78

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,ĞĂůƚŚΘ^ĂĨĞƚǇ

DĂŶĂŐĞŵĞŶƚ^ǇƐƚĞŵ

PATENT

PENDING

Before using the machine, carefully read the instructions contained in this manual. SAVE THESE INSTRUCTIONS: this manual contains important safety and operating instructions for the machine.

It is mandatory to wear approved personal protective equipment, such as:

- Flame retardent clothing.

- A helmet, goggles or face shield.

- Gloves

- Airway protective mask.

- Ear protectors.

- Boots with anti slip soles and steel toe-caps.

The user is responsible for the machine and must be properly informed about its use and the risks arising from improper use, which could cause injury or even death. Comply with appropriate rest periods and avoid prolonged exposure to vibrations and noise.

During cutting, dust and waste particles are released, including exhaust gas and petrol fumes, which can be inhaled.

Keep the rail saw ﬁ rm during manual cutting in order to avoid hazardous kickback.

When cutting, hot sparks ﬂ y oﬀ which can cause ﬁ re when in the presence of ﬂ ammable material such as dry grass, petrol, wood, etc.

When the machine is turned on, pay attention to the rotation of the power take oﬀ gear.

Keep hands away from the danger zone

• Carefully follow the safety instrucrtions set out by Cembre. Failure to observe these

warnings and the incorrect or improper use of the RAIL SAW may cause serious injury to the operator and others close by.

• Always use personal protective equipment provided by your employer as result of a risk evaluation prescribed by current national safety legislation, including: flame retardent clothing, goggles or face shield, ear protectors, helmet, gloves, boots with anti slip soles and steel toe-caps, airway protective mask.

• Anyone who uses or operates the RAIL SAW must first read this user manual carefully and be familiar with the controls. The machine should only be used by trained, competent personnel.

• Do not use the RAIL SAW for purposes other than those intended by Cembre or for grinding operations using the side surface of the cutting disc as this may break and cause serious injury. Never use a machine that is faulty, has been tampered with or which has been modified from its original form.

• Control the surrounding area before operation; the safety distance around the RAIL SAW for personnel not operating the machine should be at least 15 metres. Hot sparks which fly off during cutting can cause fire if in the presence of flammable materials such as dry grass, petrol, wood, etc.

• The RAIL SAW must only be used in conjunction with support arms supplied by Cembre.

• Never operate the RAIL SAW during personal ill health, when tired or under the effects of alcohol, drugs or medicines which can alter the state of mind and reduce reaction times; use good judgement in all situations.

• When operating, stand in a stable, secure position and grip the RAIL SAW tightly. Be sure to work in good lighting conditions or with sufficient artificial lighting.

• Always keep a first aid kit and fire extinguisher on hand in order to intervene promptly should if the need arise.

• Avoid inhalation of Petrol fumes and exhaust emissions which contain Carbon Monoxide, an odourless lethal gas. Ensure good ventilation.

• The fuel and its vapours are extremely flammable. FIRE AND BURN HAZARD.

• Turn off the engine before refuelling. Dry any spilt fuel. If the fuel comes into contact with clothing, change the clothing immediately. Do not start the engine within 3 metres of the refuelling area.

• During transportation, always remove the cutting disc from the RAIL SAW.

Descriptions and possible conﬁ gurations:

RDS-14P RDS-14P.78 *

AA-RDS

SA-RDS

RDS-14P-AA RDS-14P.78-AA *

RDS-14P-SA RDS-14P.78-SA *

(*) Rail saw suitable for cutting discs with hub diameter of 22.2 mm (7/8”).

•

••

Main components (Ref. Fig. 1 page 5):

– Air ﬁ lter spark plug cover

– Upper handle

– Safety guard (spark guard)

– Abrasive cutting disc (to be mounted)

– Transmission system side guard

– Foot

– Power Take Oﬀ for active arm

– Support arm pin slot

– Silencer / muﬄ er

– (EasyStart) Decompression valve

– Combustion engine

– Abrasive cutting disc ﬁ xing

– Slot for support arm reference pin

14 – 4mm Allen key for removing side guard

15 – Auxiliary switching device

16 – Multifunction spanner (torx + cut)

17 – Fuel tank cap

18 – Main ON/OFF switch

19 – Rear control handle

20 – Accelerator

21 – Safety lever

22 – Accelerator block

23 – Air valve control (starter)

24 – Starter rope grip

25 – Auxiliary switching device antenna

26 – Measure for petrol-oil mix

27 – Lanyard for auxiliary switching device

•

FIG. 1

3.1) General Characteristics:

– Application range: cutting rail with suitable abrasive cutting disc.

– Dimensions: ................................................................................................... refer to Fig. 2 and 3, page 39

– Weight (without support arm or cutting disc):

....................................................... 19

kg (41.8 lbs)

– Combustion engine:

– type: ..................................................................................................Husqvarna, 2 stroke, single-cylinder,

air cooled, electronic start, 5-stage air ﬁ lter

– displacement: ............................................................................................................... 119 cc (7.26 cu.inch)

– bore/stroke: ................................................................................................60 mm (2.36”) / 42 mm (1.65”)

– power: ........................................................................................................................................5.8 kW (7.8 HP)

– n° of revs idling: ..................................................................................min. 2500 - max.9750 ± 250 RPM

– carburettor: ..................................................................................................................................Walbro WG 9

– spark plug: ............................................................... CHAMPION RCJ6Y, NGK BPMR7A or equivalents

– fuel: ...............................................................................................................................................petrol mixture

– tank capacity: .........................................................................................................1.25 litres (2.65 US Pint)

– clutch: ........................................................................................centrifugal with automatic intervention

– start: ................................................................................................... by rope pull with automatic rewind

– Cutting group:

– n° of revs of drive shaft: ................................................................................................................4,700 RPM

– drive shaft diameter (RDS-14P): ............................................................................................ 25.4 mm (1”)

– drive shaft diameter (RDS-14P.78): ................................................................................... 22.2 mm (7/8”)

– max. diameter of suitable cutting disc: .............................................................................406 mm (16”)

– max. cutting depth: .................................................................................................................140 mm (5.5“)

Acoustic noise (Directive 2006/42/EC, annexe 1, point 1.7.4.2 letter u)

–

– The weighted continuous acoustic pressure level equivalent A at the work place L

is equal to ........................................................................................... 105.5 dB (A)

– The maximum value of the weighted acoustic displacement pressure C at the work place L

is equal to ....................................................................121.3 dB (C)

pCPeak

– The acoustic power level emitted by the machine

is equal to ..................................................................................................................................... 116 dB (A)

–

Risks due to vibration (Directive 2006/42/EC, annexe 1, point 2.2.1.1)

Tests carried out in compliance with the indications contained in UNI ENV 25349 and UNI EN 28662 part 1

than those normally found, certify that the weighted root mean square in frequency

the acceleration the upper limbs are exposed

Standards, and under operating conditions much more severe

is 11.42 m/sec2 max.

3.2) Safety devices on the machine

The safety devices supplied on the RAIL SAW and listed below must be fully functional and checked before each use. If this is not the case do not use the machine and contact Cembre for any repairs.

- ON/OFF SWITCH (18) this is found in a very visible position and is easily operated. It is used for stopping the machine normally or in emergency.

Ensure you are familiar with how to use the switch (18) so that you can act promptly in case of emergency.

- ACCELERATOR (20):

to full operating speed. It can only be activated by pressing the interlock lever at the same time (21).

- INTERLOCK LEVER (21): prevents accidental activation of the accelerator which cannot be activated without pressing this lever.

this is used to run the engine

When the accelerator is released, the abrasive cutting disc continues to turn for some

time. Do not approach the cutting group until the disc has completely stopped.

- ACCELERA TOR BLOCK (22):

• it locks the accelerator in start-up position when the engine is cold.

• it locks the accelerator in maximum acceleration position.

This function must only be used in automatic

mode with the AA-RDS automatic support arm.

The accelerator block (22) can only be activated by pressing the accelerator (20) and the interlock lever (21) at the same time. Once activated, press the accelerator down.

has two functions:

start up and max.acceleration positions

- SAFETY GUARD (3) designed to protect the operator from fragments and sparks

which ﬂ y oﬀ during cutting. Push the handle forwards or backwards to ﬁ nd the most eﬀ ective position.

Never use the RAIL SAW

without the safety guard or when the guard is damaged!

3.3) Auxiliary switching device

Aerial

STOP button (1) (switches the rail saw oﬀ )

Hook

RESET button (2) (stops the air ﬁ lter cleaning alarm)

REAR VIEW

Protective rubber case

Battery compartment

TECHNICAL DETAILS: frequency: 433 Mhz max. distance: 5 metres power: CR2032 Lithium cell battery dimensions: 48x20xh107 mm

Cover

weight: 54 g Item code: 6003788

The device supplied with the rail saw has 2 main functions:

- Switching off the machine: the main control for turning off the rail saw off is the switch (18) on the machine itself. The machine can also be turned oﬀ with the auxiliary device by simply moving towards it while pointing the device and pressing the STOP button (1).

- Reset of the air ﬁ lter cleaning alarm: after turning oﬀ the machine, when the alarm has been triggered, point this device at the machine and press the yellow RESET button (2) 3 times in succession in order to reset the alarm code. With each pulse the machine will beep in recognition.

If the device is not able to control the machine: – check there are no obstacles between the device and the machine. – move much closer to the machine, it is likely that you are out of range. – fully accelerate the machine for at least 10 seconds. – replace the old battery (mod. CR2032) with a new one.

• Replacing the battery: – Remove the rubber case by pulling it oﬀ from the aerial side. – Press down on the rear compartment cover while sliding it in the direction of the arrow. – Remove the dead battery and insert a new one, making sure it is the right way up. – Replace the cover and the protective rubber case. If it is expected that the device will not be used for a long time, it is advisable to remove the battery in order to avoid damage caused by possible leaks and corrosion.

Batteries must be disposed of separately to other waste in accordance with local sta-

tutory requirements.

3.4) Abrasive cutting discs

For maximum performance, use the rail saw in conjunction with the high quality C-Rex range

Cembre discs listed below, in compliance with the requirements of the standard EN 12413 for

bonded abrasives:

DISC

TYPE

CRDL4387 355x3.8x22.2 (14”x5/32”x7/8”) 5500 100 RDS-14P.78

CRDL4381 355x3.8x25.4 (14”x5/32”x1”) 5500 100 RDS-14P

CRDL6407 406x4.0x22.2 (16”x5/32”x7/8”) 4800 100 RDS-14P.78

CRDL6401 406x4.0x25.4 (16”x5/32”x1”) 4800 100 RDS-14P

– The RPM shown on the abrasive cutting disc label must be equal to or higher than that produced by the rail saw. – Never use the rail saw for grinding operations on the side surface of the disc, as it may break and cause serious injury. – The cutting discs must only be used for cutting suitable materials. – During transportation and storage of the rail saw, always remove the cutting disc and lay it on a ﬂ at surface in a dry place protected from frost and moisture. – Always tighten the ﬁ xing screw of the cutting disc with a 20-25 Nm torque, to prevent the disc from loosening. – Worn or broken discs must be disposed of in compliance with local statutory requirements.

diameter x thickness x hub

Dimensions

(RPM)

mm (inch)

Peripheral

speed

(m/s)

Compatibility

with rail saw

type:

Always, use good quality cutting discs with a diameter

of 355 mm (14”) or 406 mm (16”) marked “RAIL” speciﬁ c for rail cutting.

The cutting disc may only be replaced when the engine

is switched oﬀ !

Never use a cutting discs designed for a lower rpm than

that of the rail saw.

Never use a cutting disc beyond its expiration date, if

indicated.

Before using a cutting disc always check it is completely

free from damage.

A simple test for verifying the integrity of a cutting disc is to hold it in the air and gently tap it with a screwdriver or a piece of wood; an intact disc will produce a low drumming tone.

4.1) Fuel mixture preparation

Risk of explosion or ﬁ re, petrol is extremely ﬂ ammable, handle with caution.

Risk of intoxication, avoid inhalation of petrol vapours. Risk of irritation, avoid prolonged and repeated contact with skin.

The rail saw has a 2-stroke air cooled engine which runs on an oil-petrol mix; for the correct dosage of oil use the measure supplied, according to the following proportions:

1:50 (2 %) of specialist synthetic 2 stroke engine oil (e.g. 5 litres of petrol,

0.1 litres of oil). Alternatively: 1:33 (3 %) of other 2 stroke engine oils for air cooled engines classiﬁ ed according to JASO FB/ISO EGB (e.g. 5 litres of petrol, 0.15 litres of oil).

Always use good quality 2 stroke engine oil and a minimum 90 octane Petrol.

Mix petrol and oil together well and prepare only enough for immediate use as the mixture will age and if several weeks old may cause engine damage. Always use the correct fuel mixture to avoid: 1 - Smoking engine and dirty spark plug, should the mixture be too oil rich. 2 - Excessive overheating with consequent seizing of the engine, should the mixture be oil deﬁ cient.

4.2) Refuelling

Always refuel with the engine swiched oﬀ . Place the rail saw on its side with the tank cap facing upwards. Using a non-spill fuel container, slowly add the mix, making sure not to spill it;

Always perform refuelling in an well-ventilated area away from the work zone, keeping

a safe distance of at least 3 metres (10 ft).

Use only a non-spill fuel container. In the event of spillage during topping up, carefully dry the engine before turning it on. Fully tighten the fuel cap.

min. 3 m (10ft)

non-spill fuel container

4.3) Mounting the cutting disc

WARNINGS:

– This operation must be performed with the engine switched oﬀ . – Before using a cutting disc, always verify its compatibility with the rail saw and observe the rules set out in § 3.4. – Verify that the hub of the disc is perfectly suitable for the shaft. – Always mount the disc complete with pressure plate. – In order to avoid an overtightening of the screw (12), start the engine only when the abrasive cutting disc is mounted.

– With the 13 mm multifunction spanner supplied, unscrew the locking screws (12) and retrieve the pressure plate (S). – Mount the disc on the shaft inside the safety guard so that it rests on the central stop. – Mount the pressure plate and lock all the screws (12) tightening with a 20-25 Nm. During the tightening phase counteract the movement of the disc with one hand.

NOTE: with the RDS-14P.78 type rail saw, check that the disc hub is suited to the 7/8” shaft.

NEVER use cutting discs with a 1” hub on a rail saw with a shaft of 7/8”.

20-25 Nm

4.4) Starting and stopping the engine

Always start the machine at a safe distance from the re-

fuelling area.

Start the engine only when the abrasive cutting disc is

mounted.

Fig. a

click

Before starting, check that the abrasive cutting disc can

rotate freely.

The rail saw can be started both on the ground and mounted on the support arm. We advise that it is started on the ground ﬁ rst to warm it up, turned oﬀ and mounted on the support arm, then re-started.

– Turn the ignition switch to the left into the starting position (Fig. a). – Press the decompression valve which makes start-up easier (Fig. b). – Only when the engine is cold: fully pull the air valve control (Fig. c). Completely press the accelerator, the interlock lever, the acce- lerator block and then release the accelerator, it will lock in the starting position (Fig. d).

•

Ground start-up (Fig. e): grasp the upper handle with one hand and place one foot on the inside of the rear handle in order to push the rail saw against the ground.

Fig. b

Fig. c

Fig. d

– Gently pull the starter rope until you feel some resistance

(the starter hooks will kick in) and then pull vigorously with rapid and decisive movements until the engine starts. Note: To avoid damaging the winding device, accompany the starter rope in the return phase and do not pull it over its stroke.

–

With the engine running, press and immediately release the acce lerator to unlock it from the starting position and let it run idle. – Release the air valve control, if pulled. – Keep the engine running for a few minutes to warm it up before starting work. – Turn oﬀ the engine and mount the rail saw on the support arm.

Fig. e

Wait until the disc has completely stopped before

mounting the machine on the support arm.

Fig. f

– Restart the engine (Fig.

The engine can be turned oﬀ :

• On the machine: release the accelerator and turn the main switch to the right into the STOP position.

• With the auxiliary device: point the device towards the machine and press the red button (1). NOTE: for the device to function, it is necessary that the machine has been fully accelerated in such a way that the disc has rotated for at least 10 seconds in order to activate the onboard circuitry.

• With the use of the AA-RDS automatic support arm: the machine will automatically turn oﬀ at the end of the work phase.

The reference plate (5) is essential for exactly locating the cutting line on the rail. The length of the plate depends on the machinesupport arm assembly. On the ﬁ rst cut it is necessary to establish an origin of the cutting distances by removing excess plate: – Push plate (5) hard until it comes into

contact with the ﬁ xed jaw (16).

– Cut the rail (Ref. to § 7 or 9), the excess part of the plate will be cut. For subsequent, it will be possible to deﬁ ne the exact point at which the disc will touch the rail and, therefore, to position the arm at an appropriate distance, using the plate.

Cutting line

The AA-RDS automatic support arm allows the machine to cut rail without operator contact as it picks up the motion from the rail saw and automatically simulates the movement of the operator during cutting; the rail saw is guided to obtain a perfectly perpendicular and straight cut. Furthermore,this arm safely supports the rail saw in a comfortable position to facilitate ﬁ xing and starting of the engine.

Description:

1. Transport handle

2. Sliding tracks

3. Suspension for cut loading

4. Disc movement adjustment ring

5. Cutting reference plate

6. Mobile jaw

7. Locking/unlocking handwheel

8. Motion transmission gear

9. Rail saw locking pin

- Weight: 19.8 kg (43.5 lbs)

- Dimensions (mm):

491

10. Reference pin

11. Interface rotation lever

12. Mobile arm

13. Rail saw locking handle

14. Stabilising rods

15. Fixed arm

16. Fixed jaw

17. Overturning red lever/use in manual mode

18. Arm stationary positioning blue lever

354

445

112

544

170

NOTE: if necessary, it is possible to use the rail saw in manual mode with the AA-RDS support arm by the red lever (17) (Ref. to § 8.4).

586

xxxxxx

Serial Number Numéro de série Seriennummer Número de serie Numero di Matricola

6.1) Attaching the arm to the rail

Open mobile jaw (6) by turning handwheel (7). Support the arm by handle (1) and rest the clamp on top of the rail head so that all four support

teeth (Ref. Fig. a) touch the rail. Tighten the clamp ﬁ rmly with handwheel (Ref. Fig. b).

Before mounting the rail saw on the arm, check that the clamp is positioned and locked in a correct manner on the rail head (Ref. Fig. b). If the arm is wrongly positioned, it can cause cutting which is not perfectly straight (Ref. Fig. c, d).

Fig. b

Fig. c

clamp

Fig. d

4 support

Fig. a

NOTE: The ﬁ xing clamp is designed to allow a precise and secure tightening of the arm on Vignole

type rails; for the ﬁ xing of the arm on diﬀ erent rail types contact Cembre.

teeth

Type Vignole

Contact Cembre

6.2) Adjusting the automatic support arm

Operation always to be carried out with the machine turned oﬀ and with the arm in a stationary position.

The AA-RDS support arm is provided with an adjustment ring (4) to allow the suspension load to be varied which in turn aﬀ ects the force required to be applied at the cutting point according to the type of cutting disc, rail hardness and internal or external track positioning. The ring is usually set to 15 for optimal function of the rail saw under the following conditions of use: – Cembre ø 350 mm cutting disc type CRDL 4381 or CRDL 4387 or similar. – Rail to be cut type UIC 60 or similar. The adjustment ring (4) can be rotated in both directions along a graduated scale from 0 to 50, on one face of the hexagon is a corresponding reference mark. Pos. 0 (no load suspension) corresponds to the maximum force at the cutting point, the rail saw presses on the rail much more; Pos. 50 (maximum load suspension) corresponds to the minimum force at the cutting point. Adjustment may be required for several reasons including:

- The rail saw turns oﬀ or the engine tends to turn itself oﬀ shortly after starting cutting at the rail head level?

In this case, decrease the cutting force, rotate the ring a couple of turns towards higher values.

- The rail saw moves slowly or stops towards the end of the cut, jamming at the intersection between the rail web/foot?

In this case, increase the cutting force (rotate the ring a couple of turns towards lower values) although, there is a risk of overheating the cutting area and the cutting disc,

compromising its use. Re-start the machine and check its function, making further adjustments if necessary. NOTE: with the positioning of the machine on the external track, usually a lower cutting force is required compared to the internal track, due to the inclination of the rails.

6.3) Overturning the automatic support arm

Overturning the arm must be done with the rail

saw dismounted. WARNING - Hand crushing hazard!

The AA-RDS automatic support arm can be overturned from one side to the other without needing to be removed from the rail, to allow cutting to be resumed in a comfortable and precise manner. To carry out this operation, after having removed the rail saw from the AA-RDS arm, follow these steps:

1 - Rotate the blue lever (18) in order

to lock it in the external position, to facilitate this operation it is advisable to keep the arm slightly raised from the base by gripping it in position (A) with one hand.

2 - At the same time

unlock red lever (17).

3 - Rotate the arm by 180°.

4 - First re-lock blue lever (18)

releasing it so that it inserts into the opposite slot (A) on the sliding track (Ref. Fig. a).

5 -Re-lock red lever (17) relea-

sing it so that it inserts into the diametrically opposite hole (B) on the sliding track (Ref. Fig. a); to facilitate this operation it may be necessary to rotate the group (C) by hand in order to make the pin line up with the hole.

(C)

Sliding track

(B)

(A)

Fig. a

IMPORTANT (Ref. to ﬁ gure below): Make sure that at the end of rotation, lever (L) is resting on the bushes (A) so that the spring rod is positioned downwards; otherwise, it will not be possible to support the rail saw and perform the cut.

6.3.1) Rotating the interface group

The overturning of the arm from one side of the rail to the other also requires the rotation of the interface group (G) in order to bring the transmission gear (8) into the

(G)

correct position to allow the rail saw to be mounted.

1- Rotate the unlocking lever (11) and, keeping

it pulled, slowly rotate the interface group (G).

2 - Release the lever (11) and continue to rotate the

group (G).

3 - At full rotation, the lever (11) will go one step further

into a suitable slot. A distinctly audible “click” will confirm that the operation has been performed correctly.

NOTE: for practical reasons, we recommend the interface unit is rotated before over turning, in any case it is important

CLICK

that at the end of rotation the transmission gear (8) is positioned at the low point.

The ﬁ gure below shows the correct position of the transmission gear (8) on both sides of the rail to be able to mount the rail saw in the correct manner; if it not is as represented in the ﬁ gure, repeat the above steps.

The figure shows the correct positioning of the rail saw supported by the arm on the two sides of the rail, in stationary position.

6.4) Mounting/dismounting the rail saw on the automatic support arm

Before mounting the rail saw on the support arm:

Check the gear (8) is in the downward position as described in § 6.3.1.

Make sure clamp (6) is ﬁ rmly locked as described in § 6.1 and levers (17 and 18) are

completely inserted.

1- Mount the rail saw on the support arm, pushing

it up to the end, and the three elements a (anti-rotation pin) b (interface pin) c (motion transmission gear) match with the slots on the two sides of the rail saw.

2- Push and rotate the handle (13) tightening it fully.

To dismount the rail saw, completely loosen the handle (13) and remove it from the arm.

WARNING:

- Always consult your employer’s rules and procedures to cut rails in presence of electrical traction return current.

- Never leave the rail saw unattended while cutting.

- Make sure that everyone keeps a safe distance away from the cutting zone.

- During the cutting operation move to a safe distance and always keep the auxiliary switching device close to hand if any problems occur during cutting.

- Remove aggregate (min. 15 cm) from the cutting area under the rail, to avoid interference with the disc guard and to make it easier to remove the disc at the end of cutting.

- Stabilise short rail sections before cutting (Ref. to § 9.1).

– Fix the arm to the rail at the pre-established cutting point (Ref. to § 6.1) by using the special reference plate. NOTE: Check that the plate is pushed into contact with the clamp; during a ﬁ rst cut it is necessary to deﬁ ne the exact origin of the distances by cutting the reference plate (Ref. to § 5). – Mount the rail saw onto the arm (Ref. to § 6.4) and start the engine (Ref. to § 4.4). – Operate the accelerator. Press accelerator block (22) (Ref. to § 3.2) to maintain maxi mum acceleration for at least 10 seconds before starting to cut. – With one hand support the arm with handle (1) and with the other rotate blue lever (18) locking it in the external position and slowly bring the cutting disc to the rail.

PRESS

TO LOCK

ACCELERATOR

IMPORTANT:

10s

To avoid damage to the transmission, the saw must be fully accelerated for at least 10 seconds before starting to cut.

NOTE: if necessary, the AA-RDS

arm allows the use of the rail saw in manual mode, it is suﬃ cient to rotate red lever (17), locking it in the external position.

– With the disc in contact with the rail, completely release the arm. – The rail saw will automatically perform regular alternate movements simulating the cutting action of an operator.

During operation always keep a safe distance and always monitor the cutting process in order to readily intervene in case of problems. Never leave the rail saw unattended!

aggregate

min. 15 cm

– When the operation is complete, the rail saw will automatically turn oﬀ due to an electronic system which detects the rpm variation of the engine.

– Unlock the accelerator from the maximum acceleration position by pressing it right down.

– Lift the arm and put it back into stationary position, re-locking the blue lever (18).

NOTE: Some factors such as: diameter of the cutting disc, a partially worn disc and dimensions of a full cut, can inﬂ uence the cutting operation and prevent the execution of the rail cutting; in such a case it will be necessary to overturn the arm (Ref. to § 6.3) and complete the operation by taking up the cut on the opposite side.

Taking up procedure

If the rail saw stops at the rail head shortly after starting the cut, it means that the cutting force is too high: rotate the adjustment ring a couple of turns towards higher values in order to put more load on the contrast spring. If the rail saw stops at the intersection between the rail web/foot towards the end of the cut, it means that the cutting force is insuﬃ cient: rotate the adjustment ring towards lower values in order to unload the suspension. (Ref. to § 6.2).

The SA-RDS manual support arm safely supports the rail saw in a comfortable position, which facilitates ﬁ xing and the starting of the engine. The rail saw needs to be guided during manual mode to obtain a perfectly straight and perpendicular cut. Moreover, the operator can work unhindered on both sides of the rail to take up the cut easily and precisely.

- Weight: 8.5 kg (18.7 lbs)

- Dimensions (mm):

350

254

443

170

640

112

Description:

1. Rail saw locking handle

2. Mobile arm

3. Sliding track

4. Clamp locking wheel/release

5. Cutting reference plate

6. Fixed jaw clamp

7. Stationary positioning lever

8. Knob to adjust arm height

9. Vertical arm

10. Mobile jaw clamp

11. Rail saw interface pin

xxxxxx

Serial Number Numéro de série Seriennummer Número de serie Numero di Matricola

8.1) Attaching the arm to the rail

Place the arm on the rail, the ﬁ xed clamp is the same to that of the AA-RDS arm and follow the procedure described in § 6.1.

8.2) Adjusting the height of the manual arm

The SA-RDS support arm can be adjusted to met the cutting requirements based on the rail dimensions and to allow the operator to adopt a comfortable working position according to his height. There are 3 positions available; normally the

most suitable position is the one with knobs (8) positioned centrally; to choose another position,

extract knobs (8) and move them into the upper or lower slot.

Align knobs (8) in the same position to avoid a cut which is not perfectly straight and perpendicular to the rail.

8.3) Overturning the SA-RDS manual support arm

Overturning the arm must be carried out without the rail saw. WARNING - Hand crushing hazard

The SA-RDS manual support arm can be overturned from one side to the other without needing to be removed from the rail, to allow a comfortable and precise resumption of cutting. To carry out this operation, it is suﬃ cient to grasp it at point (A), rotate it by 180° and move it so that it rests on the opposite side; the reference (8) has to rest on the clamp (6).

Before mounting the rail saw on the arm, check that lever (7) is correctly inserted.

The ﬁ gure shows the correct positioning of the rail saw on the support arm on both sides of the rail.

8.4) Mounting/dismounting the rail saw on the manual support arm

Before mounting the rail saw on the support arm, make sure that clamp (6) is ﬁ rmly

locked as described in § 6.1, lever (7) is completely inserted and knobs (8) are aligned.

1- Mount the rail saw on the suppor t arm,

match the interface pin (11) with the slot of the rail saw.

2- Push and rotate handle (1) tightening it fully.

To dismount the rail saw, completely loosen handle (1) and remove it.

WARNINGS:

- Always consult your employer’s rules and procedures to cut rails in presence of electrical traction return current.

- Follow the precautions described in § 9.1.

- Ensure that everyone keeps the safety distance from the cutting zone.

- Remove aggregate (min. 15 cm) from the cutting area under the rail, to avoid interference with the cutting disc guard and to make it easier to remove the disc when the cut is ﬁ nished.

– Fix the arm to the rail at the pre-esta blished point (Ref. to § 6.1) by using the appropriate reference plate. NOTE: Check that the plate is totally pushed up against clamp; during the first cut, the origins of the cutting distances must be defined exactly (Refer to § 5). – Mount the rail saw onto the arm (Ref. to § 8.4). – Start the engine (Ref. to § 4.4). – Operate the accelerator to maintain maximum acceleration for at least

10 seconds before starting to cut.

– Support the rail saw by holding the upper handle with one hand and with the other hand pull out lever (7) locking it in the external position to release the arm. – Press the accelerator completely, slowly bring the cutting disc towards the rail, whilst respecting the precautions descri bed in § 9.1.

IMPORTANT:

To avoid damage to the transmission, the saw must be fully accelerated for at least 10 seconds before starting to cut.

During manual cutting, never insert the accelerator block (22). This avoids an uncontrolled acceleration of the machine, which could cause serious damage and injury!

10s

– Start the cut by using regular alter nate movements, maintaining a steady pressure during the whole cutting phase. The double ar ticulation of the support arm will relieve the operator of the weight of the machine thus making the cutting operation easier.

aggregate

min. 15 cm

– Once the operation is ﬁ nished, release the accelerator, lift the rail saw and re-lock the arm in its resting position by pushing in the lever (7) fully . – Switch oﬀ the engine by using the switch (18) and wait for the disc to completely stop turning before carrying out any further interventions.

NOTE: Some factors such as the diameter of the cutting disc, a partially worn disc and the rail dimensions, can inﬂ uence the cutting operation and prevent the execution of a full cut. In such a case, the arm will have to be overturned (Ref. to § 8.3) and the process completed by taking up the cut on the opposite side.

Taking up procedure

9.1) Dangers deriving from the cutting process

• How to avoid kickback

Kickback may cause fatal injuries.

When use the machine in manual mode, during the phase of approaching the rail, ensure that the contact between the disc and the rail does not occur in the disc’s upper quadrant (“risk of kickback zone”), as this may cause a sudden and unexpected reaction from the machine which would be thrown towards the operator, with possible serious consequences for safety.

To avoid such a reaction, follow the rules outlined below:

– The cutting operation must never start in the upper quadrant of the cutting disc (see ﬁ gure). – While working, stand in a safe and stable position and grasp the handle ﬁ rmly. – Approach the rail carefully at the start of the cutting operation. – With a cut that has already been started, insert the disc very carefully at maximum speed.

• Pull in Pull in occurs when the cutting disc catches unexpectedly during operation and the rail saw is violently pulled downwards; this can happen if the cut closes and the disc jams. To avoid pull in, ensure that the cut stays open during the whole process. Check that the rail saw is stable or resting on supports placed as illustrated in the lower, on the right.

• Overturning

Ensure that the rail is stable or is resting on solid supports. Attach the arm on the stable side of the rail. To cut short rail sections, the section must be stabilised with appropriate ﬁ xtures to avoid the risk of unexpected machine movement; the stabilising support Cembre type SSR1 fulﬁ ls this function and is available as an accessory.

SSR 1

stabilising support

Daily maintenance is indispensable to keep the rail saw in best condition. Maintenance not carried out properly, or carried out by unauthorised or unqualiﬁ ed personnel can noticeably reduce the machine’s eﬃ ciency and increase the risk of accidents and serious injury. The maintenance procedures described may be carried out by the operator.

For any eventual ﬁ ne tuning or repairs, return to Cembre.

The maintenance plan provided is intended for a machine which is used daily, so intervals may vary according to usage frequency.

Maintenance plan

• Daily

Before using, check:

– The whole machine and support arms (the ﬁ xing of the various components). – The safety equipment is working properly and is not damaged: the ON-OFF switch, accelerator, interlock lever, accelerator block, auxiliary switching device, the disc guard. – The cutting disc is not damaged.

After usage:

– Clean the machine and support arms with a clean rag to remove dust and cutting waste. – Clean the air ﬁ lters on the engine’s side and transmission cover.

• Weekly

Check:

– The ﬁ xing of the muﬄ er. – The state and wear of the belts (Refer to § 10.8). – The carburettor is working. – The start-up devices (cable, counter spring). – Clean the cooling ﬁ ns on the cylinder. – The sponge ﬁ lter in the transmission cover.

• Monthly

Check:

– Clutch wear. – The carburettor ﬁ lter, change it if necessary. – The various cables and ﬁ tting of the supply system.

Clean

: – The spark plug; change it if necessary. – The outside of the carburettor. – The interior of the tank.

The rail saw is provided with a diagnostic system that, depending on the number of hours of operation, will warn the operator with an audible alarm that the air ﬁ lters require maintenance or that the machine requires unscheduled maintenance.

There are two alarm

AUDIBLE ALARM OPERATIONS TO BE PERFORMED

codes which sound when the machine is switched oﬀ :

Beep..Beep..Beep...

(intermittent)

Beeeep....

(prolonged)

Check the wear of the drive belt.

Clean:

• engine air ﬁ lters (Ref. to § 10.1)

• cover ﬁ lter (Ref. to § 10.7)

Check the wear of the timing belt.

Replace:

• drive belt

• engine air ﬁ lters (Ref. to § 10.1)

Clean:

• cover ﬁ lter (Ref. to § 10.7)

(Ref. to § 10.8)

10.1) Engine ﬁ lter cleaning

The diagnostic system (intermittent audible alarm), that warns the operator that the air ﬁ lters require cleaning, is calibrated for the standard operation of the machine in well-ventilated spaces outdoors. In closed and particularly dusty spaces, cleaning or changing

the ﬁ lters more frequently may be necessary, especially if starting-up the engine is diﬃ cult or if there is a reduction in power.

The engine’s ﬁ lter system comprises a primary ﬁ lter (S) and a secondary paper ﬁ lter (P). Not maintaining the ﬁ lters properly can cause: – Diﬃ cult or impossible start-up of the engine – Reduction in engine power. – High consumption. – Carburettor malfunction. – Unnecessary wear on engine parts.

Engine cover

– Deposits on the spark plug. – The machine not being able to carry out cutting in automatic mode.

• Primary sponge ﬁ lter (S) (spare part code: 6003910) – Remove the top engine cover by unscrewing the 2 Torx screws with the tool supplied. – Take the ﬁ lter out and wash it carefully with warm water and soap, then rinse it well with clean water. Squeeze the ﬁ lter well and dry it. – Before remounting it, carefully oil the ﬁ lter. It is important that the ﬁ lter is well-oiled, in order to do this we advise putting it in a bag, adding oil,

Insert

spreading it evenly over the ﬁ lter then squeezing it to get rid of excess oil. Do not use normal engine oil for this purpose, contact Cembre for suitable oil.

NOTE: Do not clean the ﬁ lter with compressed air as high pressure could damage the sponge.

• Paper Filter (P) (spare part code: 6003911) – Remove the insert, Take the ﬁ lter out and shake or clean it carefully with compressed air from the inside out, to remove the dust. – Reassemble correclty.

NOTE: the paper ﬁ lter must not be washed!

Depending on usage, the ﬁ lter will have to be periodically replaced with a new one. A damaged air ﬁ lter must be replaced immediately.

RE-SETTING THE ALARM After switching oﬀ the machine, while the alarm has been triggered, point the auxiliary switching device towards the machine and press the yellow RESET button (2) three times in succession to

reset the alarm. Each time you press the button, the machine will beep in recognition. NOTE: If the alarm does not reset using the procedure set out, at every successive switching oﬀ of the rail saw the alarm will be triggered. It is possible that the alarm will not be triggered if the machine is switched on at minimum power without acceleration so that the cutting disc rotates for at least 10 seconds.

10.2) Fuel ﬁ lter (spare part code: 6003922)

A reduction in fuel ﬂ ow towards the carburettor indicates that the ﬁ lter is clogged up. The fuel ﬁ lter is located in the fuel tank and if it is clogged up, it must be replaced with a new one as it cannot be cleaned.

Avoid dirt getting into the fuel tank during ﬁ lter replacements. Replace the fuel ﬁ lter at least once a year.

10.3) Spark plug (spare part code: 6003752)

Deposits on the spark plug’s electrode can cause malfunctions or engine start-up problems. This can be due to: – A mix of fuel that contains too much oil. – A dirty air ﬁ lter. – A carburettor that is not regulated properly. To clean the spark plug: – Remove the uppermost engine cover by unscrewing the two side screws. – Disconnect the coil and unscrew the spark plug with the wrench supplied. – Clean oﬀ all the deposits on the electrode using a wire brush, taking care not to damage the ceramic support. – Check, and if necessary, adjust the distance of the electrodes to 0,5 mm. – Screw the spark plug back in, reconnect the lead and remount the cover. – If a replacement is needed, use CHAMPION RCJ6Y, NGK BPMR7A or equivalent.

An unsuitable spark plug can damage the cylinder or the piston. Replace the spark plug after about a month of work, or more often if necessary.

10.4) Carburettor

The carburettor regulates engine speed through the accelerator and blends air and fuel together. The rail saw’s engine is regulated during manufacture so that harmful emissions are reduced to a minimum.

The complete running in of the engine is achieved after having topped up the fuel tank 8-10 times. Avoid adjusting the carburettor unless absolutely necessary.

• Main nozzle The engine is equipped with a ﬁ xed nozzle that ensures the correct supply of the blended air and fuel. If the engine is losing power or is not accelerating, clean or if necessary replace the air

ﬁ lter. If this does not resolve the problem, contact Cembre.

• Carburration adjustment

Fully press the accelerator a couple of times and check

that the rail saw accelerates as expected. Screw L is factory set open by 1 and a 1/4 turns. If an adjustment is necessary, turn it clockwise until there is no fuel in the engine; then open it 1/8 turn anticlockwise. Check engine acceleration. NOTE: A poor adjustment of low speed (screw L too tight) can cause diﬃ culty when starting the engine.

• Final adjustment of minimum speed T The engine’s minimum speed is adjusted through screw T. If an adjustment is required, turn clockwise until the cutting disc starts to turn, then slowly turn anticlockwise until the disc stops turning. The minimum speed is adjusted correctly when the engine accelerates correctly. Minimum rpm advised: 2500 rpm.

The cutting disc must remain still at minimum speed.

10.5) Exhaust Muﬄ er

Burns risk!

The muﬄ er has been designed to reduce noise levels and to channel exhaust fumes away from the operator. Check the muﬄ er and its ﬁ xings regularly to ensure there is no damage. Exhaust fumes are hot and can contain sparks which may set ﬁ re to dry and ﬂ ammable material anywhere near the machine.

Never use the machine with a muﬄ er that is clogged or faulty.

10.6) Starter rope

Always wear safety goggles when replacing the starter rope; the recoil spring is tensio-

ned and if accidentally released may cause personal injury!

• Replacing a worn or broken starter rope

– Unscrew 4 screws that hold the side motor cover and remove it (Ref. to Fig. a). – Pull out approx. 30 cm of rope by drawing it across the notch on the side of the pulley. Release the tension of the spring by making the pulley rotate slowly (Ref. to Fig. b). – Unscrew the pulley’s fastening screws and lift it. – Thread the new rope through the cavity in the pulley and attach the rope with a knot, wind the rope clockwise 3 or 4 times around the cavity (Ref. to Fig. c). – Put the pulley back onto the recoil spring so that the end of the spring clasps the pulley and re-attach with the screw in the centre. – Thread the starter rope through the hole in the side cover and the starter handle. Make a knot at the end of the rope (Refer to Fig. d).

Fig. a

Fig. b

• Tensioning the recoil spring

– Remove the starter rope through the notch on the side of the pulley and rotate the pulley by approx. 2 clockwise rota tions (Ref. to Fig. e); check that the pulley can rotate

by a further 1/2 rotation with the rope fully extended.

• Assembling the side cover of the ignition device

– Pull the starter rope and rest the cover on the motor’s side (Ref. to Fig. f). – Release the starter rope slowly so that the pawls slot into the pulley. – Screw the 4 engine cover screws back into place.

Fig. c

Fig. f

Fig. e

Fig. d

• Replacing the recoil spring

– Remove the starter pulley by unscrewing the central screw. – Remove the recoil spring carefully by grasping it with grips. – Lubricate the recoil spring with a few drops of oil and then reassemble the starter pulley and tension the spring. If the spring pops out during the assembly phase, it will have to be reassembled again from the exterior towards the centre.

10.7) Transmission cooling system

The ventilation openings situated on the side cover allow the suction of fresh air and its expulsion so that the transmission system, including the two belts, can be cooled. After use and on a daily basis it is good practice to check that these openings are perfectly clean. If necessary, clean them with compressed air or a soft brush. The ﬁ lter on the lower part of the cover prevents cutting particles and debris being conveyed inside the transmission area.

• Cleaning the cover ﬁ lter

(spare part code: 6003655) – Disassemble the side cover by remo ving 5 screws with the 4 mm Allen key supplied. – Remove the ﬁ lter and shake or clean it with compressed air, to remove dirt.

Side cover

– Relocate and reassemble the cover.

A clogged ﬁ lter can cause abnormal overheating of the belts resulting in premature wear.

In any case, depending on usage, the ﬁ lter

Transmission ﬁ lter

will have to be replaced periodically with a new one.

IMPORTANT: When cleaning the ﬁ lter, clean also the interior of the transmission area and the two turbine wheels, with compressed air; check the status of the drive and

timing belts, if they’re worn it’s essential to replace them.

Air intake (suction) from outside

cover ﬁ lter

10.8) Replacing belts

– Disassemble the side cover (Ref. to § 10.7).

Replacing the timing belt:

(spare part code: 6003791) – Remove the belt from the pinion ﬁ rst.

1 Assemble the new belt (Refer to Fig. a)

starting from the pulley side.

2 Pull it lightly while placing it on the pinion.

Replacing the drive belt (spare part code: 6003787) Ref. to Fig. b:

Drive belt must be replaced if wear out and when indicated by the diagnostic system

The process is easier with a cutting disc ﬁ tted. – Remove the timing belt as described above. – Unscrew screw (V), remove the fan group (GA) and unthread the worn belt.

1 Place the belt on the drive shaft pulley, behind the rear pinion. 2 Thread it behind plate (P) and under rolls (R) and place it against the front split pulley.

– Assemble the fan group, polarizing it with respect to the two faces of the drive shaft and lightly screw it into place.

Fig. a

Timing belt

NOTE: During reassembly, ﬁ rstly manually alternate blocking and rotation of the disc. This will counter the rotation of the drive shaft produced by the two split pulleys getting closer. Secondly, the correct radial position of the belt must be obtained with respect to the internal surfaces of the split pulleys so that the belt runs towards the exterior. – Tighten screw (V). – Reassemble the side cover.

(P)

(R)

Drive

belt

Fig. b

(V)

(GA)

Split pulleys

WARNING: During the Fan group (GA) resassembly phase, the belt absolutely must NOT be compressed between the two split pulleys, but should run towards the exterior to avoid being deformed.

SYMPTOM

- Engine diﬃ cult to start:

CAUSE

Switch (18) in “STOP” position.

REMEDY

Move switch to “START” position.

- Engine stops while in use:

- Overheating with possible seizure of engine:

No fuel.

Air lever in wrong position

Fuel ﬁ lter clogged.

Air ﬁ lter clogged.

Spark plug dirty from residue.

Bad fuel mixture.

Incorrect carburration.

No fuel.

Air or fuel ﬁ lters clogged.

Bad fuel mixture.

Insuﬃ cient oil in fuel mixture.

Obstructed cooling ﬁ ns.

Add fuel to tank (see § 4.2).

Check position (see § 4.4)

Check and if necessary replace (see § 10.2).

Clean and if necessary replace (see § 10.1).

Clean and if necessary replace (see § 10.3).

Prepare fuel mixture correctly (see § 4.1).

Check the carburration (§ 10.4).

Add fuel to tank (see § 4.2).

Clean, if necessary replace (see § 10 .1 10.2).

Prepare fuel mixture correctly (see § 4.1).

Prepare mixture with more oil.

Clean the cooling ﬁ ns. Check engine for seizure, contact Cembre (§ 13).

- Too much exhaust smoke:

- Cutting capacity too low:

- Locking or turning oﬀ the machine with the AA-RDA automatic support arm:

- The auxiliary switching device does not work:

Too much oil in fuel mixture.

Worn belts.

Speed variator control.

Air or fuel ﬁ lters clogged.

Incorrect adjustment of the suspension of the arm.

Clogged air ﬁ lters.

Rail compressed under stress.

Low battery.

Excessive distance.

The machine has not been accelerated yet.

Prepare mixture with less oil. Clean spark plug, if necessary (§ 10.3).

Check the wear and tear (§ 10.6).

Contact Cembre (§ 13).

Clean, if necessary replace (see § 10 .1 10.2).

Adjust the ring nut to increase or decrease the load at the cutting point (§ 6.2).

Clean and if necessary replace (see § 10.1).

Follow your employer’s instructions.

Replace battery (§ 3.3)

Move within 3-5m visible distance of the machine.

Fully accelerate for at least 10 seconds to activate the electronic card..

During transport or storage of the machine always remove the cutting disc.

To facilitate transport and protect the Rail Saw, support arms and accessories from accidental knocks and dirt, Cembre recommends the use of appropriate containers, robust wooden crate with convenient spaces. VAL RDS container: for storing the Rail Saw, cutting discs and the manual support arm.

sions 1000 x 390 x h550 mm (39.3 x 15.3 x 21.6 in.), weight 12 kg (26.4 lbs).

VAL AA-RDS container: for storing the automatic support arm.

Dimensions 910 x 415 x h420 mm (35.8 x 16.3 x 16.5 in.), weight 7 kg (15.4 lbs).

If transporting the machine or if it is not used for a long period of time, empty the fuel tank and store the machine in a dry and safe place which is not accessible to children or unauthorised persons. During transportation and storage of the rail saw, always remove the cutting disc and lay it on a ﬂ at surface in a dry place protected from frost and moisture.

RDS...

SA-RDS

Dimen-



VAL RDS

Correct storing of Rail Saw and Support arms into the cases.

➊

AA-RDS

VAL AA-RDS

In the case of a breakdown contact our area agent who will advise you on the problem and give you the necessary instructions on how to dispatch the machine to our nearest service centre; if possible, attach a copy of the Test Certiﬁ cate supplied by the machine or, if no other references are available, indicate the approximate purchase date and the machine serial number.

Cembre

together with

FIG. 2 RAIL SAW DIMENSIONS mm (inches)

max. 858 (33.7)

448 (17.6)

280 (11)

815 (32)

max. 959 (37.7)

FIG. 3 OVERALL DIMENSIONS with automatic arm mm (inches)

95 (3.7)

850 (33.5)

ø 400 mm

UIC 60

150 (5.9)

910 (35.8)

365 (14.4)

any reproduction is forbidden without written permission.

Cembre:

This manual is the property of

Cembre S.p.A.

Via Serenissima, 9 25135 Brescia (Italia) Telefono: 030 36921 Telefax: 030 3365766 E-mail: sales@cembre.com www.cembre.it

Cembre España S.L.

Calle Verano, 6 y 8 - P.I. Las Monjas 28850 Torrejón de Ardoz - Madrid (España) Teléfono: 91 4852580 Telefax: 91 4852581 E-mail: comercial@cembre.es www.cembre.es

www.cembre.com

Cembre Ltd.

Dunton Park Kingsbury Road, Curdworth - Sutton Coldeld West Midlands B76 9EB (Great Britain) Tel.: 01675 470440 - Fax: 01675 470220 E-mail: sales@cembre.co.uk www.cembre.co.uk

Cembre GmbH

Heidemannstraße 166 80939 München (Deutschland) Telefon: 089 3580676 Telefax: 089 35806777 E-mail: sales@cembre.de www.cembre.de

Cembre Inc.

Raritan Center Business Park 181 Fieldcrest Avenue Edison, New Jersey 08837 (USA) Tel.: 732 225-7415 - Fax: 732 225-7414 E-mail: Sales.US@cembreinc.com www.cembreinc.com

Cembre S.a.r.l.

22 Avenue Ferdinand de Lesseps 91420 Morangis (France) Tél.: 01 60 49 11 90 - Fax: 01 60 49 29 10 CS 92014 – 91423 Morangis Cédex E-mail: info@cembre.fr www.cembre.fr

cod. 6261354

Cembre RDS-14P, RDS-14P.78 Operation And Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual