RDS-14P RDS-14P.78

13 M 120 E
ENGLISH
Certified Quality
Management System
Certified Environmental
Management System
Certified Occupational
Health & Safety
Management System
RAIL SAW
RDS-14P
RDS-14P.78
ENT
T
A
P
ING
D
N
PE
1
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 firm during manual cutting in order to avoid
hazardous kickback.
When cutting, hot sparks fly off which can cause fire when in
the presence of flammable 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.
2
• C
Carefully
f ll follow
f ll
the
th safety
f t instrucrtions
i t
ti
sett outt by
b Cembre.
C b Failure
F il
to
t observe
b
these
th
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.
3
Descriptions and possible configurations:
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):
1 – Air filter spark plug cover
2 – Upper handle
3 – Safety guard (spark guard)
4 – Abrasive cutting disc (to be mounted)
5 – Transmission system side guard
6 – Foot
7 – Power Take Off for active arm
8 – Support arm pin slot
9 – Silencer / muffler
10 – (EasyStart) Decompression valve
11 – Combustion engine
12 – Abrasive cutting disc fixing
13 – 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
4
2
25
1
3
11
4
10
9
13
8
7
6
5
FIG. 1
25
24
12
23
13
22
8
26
14
21
7
15
20
16
27
17
5
18
19
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 filter
– 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.
6
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.
18
- 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.
21
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).
22
20
- 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.
- ACCELERATOR 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
start up and
activated by pressing the accelerator (20)
max.acceleration positions
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 fly off during cutting. Push the handle forwards or backwards to find the most
effective position.
3
Never use the RAIL SAW
without the safety guard or when
the guard is damaged!
7
3.3) Auxiliary switching device
REAR
VIEW
Aerial
STOP button (1)
(switches the rail saw off)
Hook
RESET button (2)
(stops the air filter cleaning alarm)
Protective rubber case
TECHNICAL DETAILS:
frequency:
433 Mhz
max. distance: 3-5 metres
power:
CR2032 Lithium cell battery
dimensions:
48x20xh107 mm
weight:
54 g
Item code:
6003788
Battery
compartment
Cover
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 filter 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.
– accelerate the machine in order to rotate the cutting disc for at least one minute.
– 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.
8
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:
Dimensions
(m/s)
Compatibility
with rail saw
type:
5500
100
RDS-14P.78
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
DISC
TYPE
diameter x thickness x hub
mm (inch)
(RPM)
CRDL4387
355x3.8x22.2 (14”x5/32”x7/8”)
CRDL4381
Peripheral
speed
– 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 flat surface in a dry place protected from frost and moisture.
– Always tighten the fixing 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 diameter of 355 mm (14”) or 406 mm (16”) marked “RAIL”
specific 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.
9
4.1) Fuel mixture preparation
Petrol is extremely flammable, handle with caution.
Risk of explosion, fire or intoxication.
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 classified
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 deficient.
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 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.
10
non-spill fuel
container
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”.
1
2
S
20-25 Nm
11
12
Fig. a
4.4) Starting and stopping the engine
Always start the machine at a safe distance from the
refuelling area.
Start the engine only when the abrasive cutting disc is
k
clic
mounted.
Fig. b
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 first
to warm it up, turned off and mounted on the support arm, then
re-started.
Fig. c
– 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 accelerator block and then release the accelerator, it will lock in the
starting position (Fig. d).
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.
Fig. e
– With the engine running, press and immediately release the accelerator 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.
12
Wait until the disc has completely stopped before
Fig. f
mounting the machine on the support arm.
– Restart the engine (Fig. f).
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 accelerated in such a way that the disc has rotated for
at least a minute 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 first 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 fixed 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 define
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
13
5
16
The AA-RDS
S 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
fixing 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
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
- Weight: 19.8 kg (43.5 lbs)
- Dimensions (mm):
354
445
544
491
112
170
586
NOTE: if necessary, it is possible to use
the rail saw in manual mode with the AARDS support arm by the red lever (17)
(Ref. to § 8.4).
14
2
1
4
3
5
7
6
13
11
10
12
9
8
15
xxxxx
x
xxxxx
Serial Number
Numéro de série
Seriennummer
Número de serie
Numero di Matricola
x
16
18
17
5
15
14
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 firmly with handwheel (Ref.
Fig. b).
Before mounting the rail saw on the
Fig. b
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).
OK
1
Fig. c
NO
clamp
6
Fig. d
7
NO
Fig. a
4 support
teeth
NOTE: The fixing clamp is designed to allow a precise and secure tightening of the arm on
Vignole type rails; for the fixing of the arm on different rail types contact Cembre.
Type Vignole
Contact Cembre
16
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
4
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:
17
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.
17
A
2
2 - At the same time
unlock red lever (17).
1
3 - Rotate the arm by 180°.
18
17
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
3
5 -Re-lock red lever (17) releasing 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.
4
(C)
18
17
(B)
18
Sliding track
Fig. a
(A)
18
IMPORTANT (Ref. to figure 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
2
1
(G)
11
3
CLICK
8
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
confirm 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 transmission gear (8) is positioned at the low point.
The figure 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 figure, repeat the above steps.
8
8
L
A
19
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 firmly locked as described in § 6.1 and levers (17 and
18) are completely inserted.
a
b
c
18
17
1
6
8
2
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
13
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.
20
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.
- Immediately press the STOP button on the switching device 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 first cut
it is necessary to define 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).
– With one hand support the arm with handle (1) and with the other rotate blue
lever (18) locking it in the external position; the arm will therefore
be released from the stationary position.
– Press the accelerator and use maximum
acceleration by inserting completely
block (22) (Ref. to § 3.2) and
slowly bring the cutting
1
disc to the rail.
17
18
INSERT
NOTE:
if
necessary,
the AA-RDS arm allows the use of the rail
saw in manual mode,
it is sufficient to rotate
red lever (17), locking it
in the external position.
21
22
– 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 influence 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
22
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 insufficient:
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 fixing 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):
254
443
350
170
112
640
23
3
2
7
8
4
1
6
5
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
xxxxx
x
9
Serial Number
Numéro de série
Seriennummer
Número de serie
Numero di Matricola
11
8
5
10
24
8.1) Attaching the arm to the rail
Place the arm on the rail, the fixed clamp is the same to that of the AA-RDS arm and follow
the procedure described in § 6.1.
2
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.
8
2
1
8
2
1
Align knobs (8) in the same position
1
to avoid a cut which is not perfectly straight
and perpendicular to the rail.
2
8.3) Overturning the SA-RDS manual support arm
Overturning the arm must be carried out without the rail saw.
A
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 sufficient
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).
7
Before mounting the
8
rail saw on the arm, check
that lever (7) is correctly
inserted.
6
25
The figure 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
firmly locked as described in § 6.1, lever (7) is completely inserted and knobs (8)
are aligned.
7
11
8
6
1
1- 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.
2
1
26
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 finished.
- During manual cutting, never insert the accelerator block in order to avoid an
uncontrollable acceleration of the machine, which could cause serious damage
and injury.
– Fix the arm to the rail at the pre-established 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).
– Support the rail saw by holding the upper
handle with one hand and with the other
hand pull out lever (7) locking it in an
external position; the arm will be released
from its stationary position.
22
7
– Press the accelerator completely, slowly bring
the cutting disc towards the rail, whilst respecting the precautions described in § 9.1
During manual cutting,
never insert the accelerator
block (22). This avoids an uncontrolled acceleration of the
machine, which could cause
serious damage and injury!
27
– Start the cut by using regular alternate 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.
aggregate
min. 15 cm
– Once the operation is finished, 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.
18
NOTE: Some factors such as the diameter of the cutting disc, a partially worn disc and
the rail dimensions, can influence 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
28
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 figure).
– While working, stand in a safe and stable position
and grasp the handle firmly.
– 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 fixtures to avoid the
risk of unexpected machine movement; the stabilising support Cembre type SSR1 fulfils this
function and is available as an accessory.
SSR 1
stabilising support
29
Daily maintenance is indispensable to keep the rail saw in best condition. Maintenance not
carried out properly, or carried out by unauthorised or unqualified personnel can noticeably
reduce the machine’s efficiency and increase the risk of accidents and serious injury.
The maintenance procedures described may be carried out by the operator.
For any eventual fine 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 fixing 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 filters on the engine’s side and transmission cover.
• Weekly
Check:
– The fixing of the muffler.
– The state and wear of the transmission belts.
– The carburettor is working.
– The start-up devices (cable, counter spring).
– Clean the cooling fins on the cylinder.
– The sponge filter in the transmission cover.
• Monthly
Check:
– Clutch wear.
– The carburettor filter, change it if necessary.
– The various cables and fitting 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 filters require maintenance or that the machine requires unscheduled maintenance.
30
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 filters and cover filter require
cleaning (Refer to § 10.1 and 10.7).
• 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 filter cleaning
The diagnostic system (intermittent audible alarm), that warns the operator that the air
filters require cleaning, is calibrated for the standard operation of the machine in wellventilated spaces outdoors.
NOTE: In closed and particularly dusty spaces, cleaning or changing the filters
more frequently may be necessary, especially if starting-up the engine is difficult
or if there is a reduction in power.
The engine’s filter system comprises a primary filter (S) and
a secondary paper filter (P) which must be cleaned regularly
S
in order to have good filtering.
Not maintaining the filters properly can cause:
P
– Difficult 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
Engine cover
in automatic mode.
• Primary sponge filter (S)
– Remove the top engine cover by unscrewing the 2
Torx screws with the tool supplied.
– Take the filter out and wash it carefully with warm
water and soap, then rinse it well with clean water.
Squeeze the filter well and dry it.
– Before remounting it, carefully oil the filter.
It is important that the filter is well-oiled, in order
to do this we advise putting it in a bag, adding oil,
spreading it evenly over the filter then squeezing it
to get rid of excess oil.
Do not use normal engine oil for this purpose,
contact Cembre for suitable oil.
• Sponge filter item code: 6003910.
S
Insert
P
NOTE: Do not clean the filter with compressed air as
high pressure could damage the sponge.
31
• Paper Filter (P)
– Remove the insert, Take the filter out and shake or clean it carefully
with compressed air from the inside out, to remove the dust.
– Reassemble correclty.
NOTE: the paper filter must not be washed!
Depending on usage, the filter will have to be periodically
replaced with a new one.
A damaged air filter must be replaced immediately.
• Paper filter item code: 6003911
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 wheel
rotates for at least a minute.
NOTE: After cleaning the engine air filter three times following indication by the diagnostic system, it will be necessary to replace the filter to ensure correct operation
of the rail saw.
10.2) Fuel filter
A reduction in fuel flow towards the carburettor indicates that the filter is clogged up.
The fuel filter 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 filter replacements.
Replace the fuel filter at least once a year.
• Fuel filter item code: 6003922
10.3) Spark plug
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 filter.
– 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.
• Spark plug item code: 6003752
32
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 fixed 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 filter. If this does not resolve the problem, contact Cembre.
L
L
T
T
• 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 difficulty 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 Muffler
Burns risk!
The muffler has been designed to reduce noise
levels and to channel exhaust fumes away from
the operator.
Check the muffler and its fixings regularly to ensure
there is no damage.
Exhaust fumes are hot and can contain sparks which
may set fire to dry and flammable material anywhere
near the machine.
Never use the machine with a muffler that is
clogged or faulty.
33
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).
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 rotations (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. e
Fig. f
Fig. d
34
• 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 filter on the lower part of the cover prevents cutting particles and debris being
conveyed inside the transmission area.
• Cleaning the transmission filter:
– Disassemble the side cover by removing 5 screws with the 4 mm
Allen key supplied.
– Remove the filter and shake or clean it
with compressed air, to remove dirt.
– Relocate and reassemble the cover.
Air intake (suction) from outside
Side
cover
A clogged filter can cause abnor-
mal overheating of the belts resulting
in premature wear.
In any case, depending on usage, the filter
will have to be replaced periodically with a
new one.
Transmission filter
IMPORTANT: When cleaning the filter, clean also the
interior of the transmission area and the two turbine
wheels, with compressed air; check the status of
the belts, if they’re worn it’s essential to replace
them.
• Cover filter item code: 6003655.
Transmission filter
35
10.8) Replacing belts
– Disassemble the side cover (Refer to §
10.7).
• Replacing the timing belt:
– Remove the belt from the pinion first.
1 Assemble the new belt (Refer to Fig. a)
starting from the pulley side.
2 Pull it lightly while placing it on the
pinion.
• Timing belt item code: 6003791
Fig. a
Timing belt
• Replacing the drive belt (Ref. to Fig. b):
The process is easier with a cutting disc fitted.
– 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, firstly 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) with a torque
of 20 Nm.
– Reassemble the side cover.
• Drive belt item code: 6003787
1
2
Drive
belt
(R)
(P)
Fig. b
Split pulleys
)V(
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.
(GA)
36
SYMPTOM
CAUSE
REMEDY
Switch (18) in “STOP” position.
Move switch to “START” position.
No fuel.
Add fuel to tank (see § 4.2).
Air lever in wrong position
Check position (see § 4.4)
Fuel filter clogged.
Check and if necessary replace (see § 10.2).
Air filter clogged.
Clean and if necessary replace (see § 10.1).
Spark plug dirty from residue.
Clean and if necessary replace (see § 10.3).
Bad fuel mixture.
Prepare fuel mixture correctly (see § 4.1).
Incorrect carburration.
Check the carburration (§ 10.4).
No fuel.
Add fuel to tank (see § 4.2).
Air or fuel filters clogged.
Clean, if necessary replace (see § 10 .1 10.2).
Bad fuel mixture.
Prepare fuel mixture correctly (see § 4.1).
Insufficient oil in fuel mixture.
Prepare mixture with more oil.
Obstructed cooling fins.
Clean the cooling fins.
Check engine for seizure, contact Cembre (§ 13).
- Too much exhaust
smoke:
Too much oil in fuel mixture.
Prepare mixture with less oil.
Clean spark plug, if necessary (§ 10.3).
- Cutting capacity too low:
Worn belts.
Check the wear and tear (§ 10.6).
Speed variator control.
Contact Cembre (§ 13).
Air or fuel filters clogged.
Clean, if necessary replace (see § 10 .1 10.2).
- Engine difficult to start:
- Engine stops while
in use:
- Overheating with
possible seizure of
engine:
- Locking or turning off the Incorrect adjustment of the
machine with the AA-RDA suspension of the arm.
automatic support arm:
Clogged air filters.
- The auxiliary switching
device does not work:
37
Adjust the ring nut to increase or decrease the
load at the cutting point (§ 6.2).
Clean and if necessary replace (see § 10.1).
Rail compressed under stress.
Follow your employer’s instructions.
Low battery.
Replace battery (§ 3.3)
Excessive distance.
Move within 3-5m visible distance of the machine.
The machine has not been
accelerated yet.
Accelerate so that the cutting disc spins for at
least a minute.
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.
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
RDS...
a flat surface in a dry place protected
from frost and moisture.
SA-RDS
—
➊
AA-RDS
VAL RDS
Correct storing of
Rail Saw and Support
arms into the cases.
VAL AA-RDS
38
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 Certificate supplied by Cembre
together with the machine or, if no other references are available, indicate the approximate
purchase date and the machine serial number.
ø 400
mm
448 (17.6)
FIG. 2 RAIL SAW DIMENSIONS mm (inches)
max. 858 (33.7)
815 (32)
280 (11)
max. 959 (37.7)
FIG. 3 OVERALL DIMENSIONS with automatic arm mm (inches)
95 (3.7)
910 (35.8)
850 (33.5)
UIC 60
39
150 (5.9)
365 (14.4)
This manual is the property of Cembre: any reproduction is forbidden without written permission.
cod. 6261354
www.cembre.com
Cembre S.p.A.
Via Serenissima, 9
25135 Brescia (Italia)
Telefono: 030 36921
Telefax: 030 3365766
E-mail: [email protected]
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: [email protected]
www.cembre.es
Cembre Ltd.
Dunton Park
Kingsbury Road, Curdworth - Sutton Coldfield
West Midlands B76 9EB (Great Britain)
Tel.: 01675 470440 - Fax: 01675 470220
E-mail: [email protected]
www.cembre.co.uk
Cembre AS
Fossnes Senter
N-3160 Stokke (Norway)
Phone: (47) 33361765
Telefax: (47) 33361766
E-mail: [email protected]
www.cembre.no
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
B.P. 37 - 91421 Morangis Cédex
E-mail: [email protected]
www.cembre.fr
Cembre GmbH
Heidemannstraße 166
80939 München (Deutschland)
Telefon: 089/3580676
Telefax: 089/35806777
E-mail: [email protected]
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: [email protected]
www.cembreinc.com
40