1

RDS-14PRDS-14P.78

Certified EnvironmentalManagement System

Certified OccupationalHealth & Safety

Management System

Certified QualityManagement System

RAIL SAW

ENGLISH

14 M 113 E

PATENT

PENDING

2

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 equip-ment, 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.

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• 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.

C f ll f ll th f t i t ti t t b C b F il t b th

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

1 – Air fi lter spark plug cover2 – Upper handle3 – Safety guard (spark guard)4 – Abrasive cutting disc (to be mounted)5 – Transmission system side guard 6 – Foot 7 – Power Take Off for active arm8 – Support arm pin slot9 – Silencer / muffl er10 – (EasyStart) Decompression valve11 – Combustion engine12 – Abrasive cutting disc fi xing13 – Slot for support arm reference pin

Descriptions and possible confi gurations:

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

RDS-14PRDS-14P.78 * •AA-RDS •SA-RDS •RDS-14P-AA RDS-14P.78-AA * • •RDS-14P-SARDS-14P.78-SA * • •

14 – 4mm Allen key for removing side guard15 – Auxiliary switching device16 – Multifunction spanner (torx + cut)17 – Fuel tank cap18 – Main ON/OFF switch19 – Rear control handle 20 – Accelerator21 – Safety lever22 – Accelerator block23 – Air valve control (starter)24 – Starter rope grip25 – Auxiliary switching device antenna26 – Measure for petrol-oil mix27 – Lanyard for auxiliary switching device

5

FIG. 1

4

3 1

2

8

12

8

21

22

23

5

9

24

15

19

6

11

10

7

1617

20

18

7

26

27

13

13

25

25

14

6

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 LpA is equal to ..............................................................105.5 dB (A) – The maximum value of the weighted acoustic displacement pressure C at the work place LpCPeak is equal to .........................................121.3 dB (C)– The acoustic power level emitted by the machine LWA 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 1st Standards, and under operating conditions much more severe than those normally found, certify that the weighted root mean square in frequency of the acceleration the upper limbs are exposed is 11.42 m/sec2 max.

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3.2) Safety devices on the machineThe 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): this is used to run the engine 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.

� 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): has two functions:• 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.

- 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 effective position.

� Never use the RAIL SAW without the safety guard or whenthe guard is damaged!

start up and max.acceleration positions

21

20

22

18

3

8

3.3) Auxiliary switching device

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

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

Protective rubber case

TECHNICAL DETAILS:frequency: 433 Mhz max. distance: 3-5 metrespower: CR2032 Lithium cell batterydimensions: 48x20xh107 mm weight: 54 gItem 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 statutory requirements.

Aerial

Hook

Battery compartment

Cover

REAR VIEW

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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:

DISCTYPE

Dimensionsdiameter x thickness x hub

mm (inch)(RPM)

Peripheralspeed(m/s)

Compatibilitywith rail saw

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..

� Always, use good quality cutting discs with a dia-meter 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 com-pletely 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.

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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.

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min. 3 m (10ft)

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”.

non-spill fuel container

20-25 Nm

1 2

12 S

12

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.

– 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.

click

� Always start the machine at a safe distance from the refuelling area.

� Start the engine only when the abrasive cutting disc is mounted.

� Before starting, check that the abrasive cutting disc can rotate freely.

Fig. a

Fig. c

Fig. d

4.4) Starting and stopping the engine

Fig. e

Fig. b

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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.

Cutting line

The reference plate (5) is essential for exactly locating the cutting line on the rail.The length of the plate depends on the machine-support 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.

5

16

Fig. f� Wait until the disc has completely stopped before mounting the machine on the support arm.

– Restart the engine (Fig. f).

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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 handle2. Sliding tracks3. Suspension for cut loading 4. Disc movement adjustment ring5. Cutting reference plate6. Mobile jaw7. Locking/unlocking handwheel8. Motion transmission gear9. Rail saw locking pin

- Weight: 19.8 kg (43.5 lbs)

- Dimensions (mm):

S

491 354

586

112

445

170

544

10. Reference pin11. Interface rotation lever12. Mobile arm13. Rail saw locking handle14. Stabilising rods15. Fixed arm16. Fixed jaw17. Overturning red lever/use in manual mode18. Arm stationary positioning blue lever

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).

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Serial NumberNuméro de sérieSeriennummerNúmero de serieNumero di Matricola

xxxxxx

1

5

13

14

7

6

2

9

5

12

15

xxxxxx

4 3

11

17

16

8

10

18

16

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).

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 different rail types contact Cembre.

Type VignoleContact Cembre

OK

NO

NO

Fig. b

Fig. c

Fig. a

Fig. d

4 support teeth

7

6

1

clamp

17

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 resu-med 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:

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 affects 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.

4

18

2

11

1 - Rotate the blue lever (18) in order to lock it in the external po-sition, 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°. 18

17A

3

5

4

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) rele-asing 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 necessa-ry to rotate the group (C) by hand in order to make the pin line up with the hole.

(B)

(A) Sliding track

17

(C) 17

1818

Fig. a

19

CLICK

2

3

1

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 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 confi rm that the operation has been performed correctly.

NOTE: for practical reasons, we recommend the interface unit is rotated before overturning, in any case it is important that at the end of rotation the transmis-sion gear (8) is positioned at the low point.

(G)11

8

8 8

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.

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.

A

L

20

The fi gure shows the correct positioning of the rail saw supported by the arm on the two sides of the rail, in sta-tionary position.

1

2

a

c

b

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.

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.

6

17

18

8

13

21

� 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.

1

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.

1718

22

PRESS TO LOCK

ACCELERATOR

IMPORTANT:

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

10s

22

min. 15 cm

– 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!

– When the operation is complete, the rail saw will automatically turn off due to an elec- tronic 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 di-mensions 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 upprocedure

aggregate

23

254

112

443

170

640

350

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):

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).

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Serial NumberNuméro de sérieSeriennummerNúmero de serieNumero di Matricola

xxxxxx

2

4 1

3

6

7

8

5Description:1. Rail saw locking handle2. Mobile arm3. Sliding track4. Clamp locking wheel/release5. Cutting reference plate6. Fixed jaw clamp7. Stationary positioning lever8. Knob to adjust arm height9. Vertical arm10. Mobile jaw clamp11. Rail saw interface pin 9

5

11

10

8

25

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.

2

1

2

2

2

1

1

8

8

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.

8

6

A

7

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.

8.3) Overturning the SA-RDS manual support arm

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

26

1

21- Mount the rail saw on the support 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.

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.

7

6

1

11 8

27

� 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 in- terference 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.

7

22

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

IMPORTANT:

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

10s

28

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.

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

– 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.

min. 15 cm

Taking upprocedure

18

aggregate

29

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 inPull 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.

• OverturningEnsure 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 sta-bilising support Cembre type SSR1 fulfi ls this function and is available as an accessory.

SSR 1stabilising support

30

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• DailyBefore 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.

• WeeklyCheck:– 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.

• MonthlyCheck:– 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 main-tenance or that the machine requires unscheduled maintenance.

31

Engine cover

Insert

S

P

S

P

There are two alarm codes which sound for a duration of around 20 sec when the machine is switched off:• Beep..Beep..Beep...(intermittent): indicates the air fi lters and cover fi lter require cleaning (Refer to § 10.1 and 10.7). NOTE: Correct operation of the machine requires that air fi lters are cleaned no more than twice when indicated by the diagnostic system, then replaced along with the drive belt.

• Beep (prolonged): indicates that unscheduled maintenance on the machine is required. This must be only be carried out by authorised personnel; send the machine to Cembre (Refer to § 13).

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.– 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, 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.

32

• 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 ALARMAfter switching off the machine, while the alarm has been triggered, point the auxiliary switching device towards the ma-chine 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.

33

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 nozzleThe 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 adjustmentFully 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 TThe 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.

TL

TL

34

10.6) Starter rope

� Always wear safety goggles when replacing the starter rope; the recoil spring is tensioned 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).

• 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. a

Fig. b

Fig. c

Fig. dFig. f

Fig. e

35

• 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.

Air intake (suction) from outside

Transmission fi lter

Transmission fi lter

Sidecover

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 pre-vents cutting particles and debris beingconveyed inside the transmission area.

• Cleaning the transmission 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.– Relocate and reassemble the cover.

� A clogged fi lter can cause abnor-mal overheating of the belts resulting in premature wear.

In any case, depending on usage, the fi lterwill 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.

36

Fig. a

1

2

(V) (GA)

(R) (P)

Split pulleys

Timing belt

Drivebelt

Fig. b

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:

� Air fi lters are cleaned no more than twice when indicated by the diagnostic system, then replaced along with the drive belt.

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.NOTE: During reassembly, fi rstly ma-nually 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), torque of 20 Nm.– Reassemble the side cover.

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

37

CAUSE Switch (18) in “STOP” position.

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.

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.

REMEDY

Move switch to “START” position.

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).

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 activa-te the electronic card..

SYMPTOM

- Engine diffi cult to start:

- Engine stops while in use:

- Overheating with possible seizure of engine:

- 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:

38

� 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 ac-cidental 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.Dimensions 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.

➊

VAL RDS

VAL AA-RDSCorrect s tor ing of Rail Saw and Support arms into the cases.

SA-RDS

RDS...

AA-RDS

39

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 Cembre together with the machine or, if no other references are available, indicate the approximate purchase date and the machine serial number.

In the case of a breakdown contact our area agent who will advise you on the problem

max. 858 (33.7)

max. 959 (37.7)

280 (11)

448

(17.

6)

ø 40

0 m

m

850 (33.5)95 (3.7)

365 (14.4)150 (5.9)

910

(35.

8)

UIC 60

815 (32)

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

FIG. 2 RAIL SAW DIMENSIONS mm (inches)

40

cod.

626

1354

Cembre Ltd.Dunton ParkKingsbury Road, Curdworth - Sutton ColdfieldWest Midlands B76 9EB (Great Britain)Tel.: 01675 470440 - Fax: 01675 470220E-mail: sales@cembre.co.ukwww.cembre.co.uk

Cembre S.p.A. Via Serenissima, 9 25135 Brescia (Italia) Telefono: 030 36921Telefax: 030 3365766E-mail: sales@cembre.comwww.cembre.it

Cembre S.a.r.l.22 Avenue Ferdinand de Lesseps91420 Morangis (France)Tél.: 01 60 49 11 90 - Fax: 01 60 49 29 10B.P. 37 - 91421 Morangis CédexE-mail: info@cembre.frwww.cembre.fr

Cembre España S.L.Calle Verano, 6 y 8 - P.I. Las Monjas28850 Torrejón de Ardoz - Madrid (España)Teléfono: 91 4852580Telefax: 91 4852581E-mail: comercial@cembre.eswww.cembre.es

Cembre ASFossnes SenterN-3160 Stokke (Norway)Phone: (47) 33361765Telefax: (47) 33361766E-mail: sales@cembre.nowww.cembre.no

Cembre GmbHHeidemannstraße 16680939 München (Deutschland)Telefon: 089/3580676Telefax: 089/35806777E-mail: sales@cembre.dewww.cembre.de

Cembre Inc.Raritan Center Business Park181 Fieldcrest AvenueEdison, New Jersey 08837 (USA)Tel.: (732) 225-7415 - Fax: (732) 225-7414E-mail: Sales.US@cembreinc.comwww.cembreinc.com

www.cembre.com

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