Cembre RDS-14P User manual

1
RDS-14P
RDS-14P.78
ĞƌƟĮĞĚŶǀŝƌŽŶŵĞŶƚĂů
DĂŶĂŐĞŵĞŶƚ^LJƐƚĞŵ
ĞƌƟĮĞĚKĐĐƵƉĂƟŽŶĂů
,ĞĂůƚŚΘ^ĂĨĞƚLJ
DĂŶĂŐĞŵĞŶƚ^LJƐƚĞŵ
ĞƌƟĮĞĚYƵĂůŝƚLJ
DĂŶĂŐĞŵĞŶƚ^LJƐƚĞŵ
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.
Theuserisresponsibleforthemachineandmustbeproperly 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.
Duringcutting,dustandwasteparticlesarereleased,includingexhaust
gas and petrol fumes, which can be inhaled.
Keep the rail saw firm during manual cutting in order to avoid hazar-
dous 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
.

3
• 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.
Cfllfll h f i i b
Cb
Fil b h

4
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
Descriptions and possible configurations:
(*) Rail saw suitable for cutting discs with hub diameter of 22.2 mm (7/8”).
RDS-14P
RDS-14P.78 * •
AA-RDS •
SA-RDS •
RDS-14P-AA
RDS-14P.78-AA * ••
RDS-14P-SA
RDS-14P.78-SA * ••
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

5
FIG. 1
4
3
1
2
8
12
8
21
22
23
5
9
24
15
19
6
11
10
7
16
17
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 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/sec2max.

7
3.2) Safety devices on the machine
The safety devices supplied on the RAIL SAW and listed below must be fully functional and
checked before each use. If this is not the case do not use the machine and contact Cembre
for any repairs.
- ON/OFF SWITCH (18) this is found in a very visible
position and is easily operated. It is used for stopping
the machine normally or in emergency.
Ensure you are familiar with how to use the switch
(18) so that you can act promptly in case of emergency.
- ACCELERATOR (20): 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.
- 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
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 fly off during cutting. Push the handle forwards or backwards to find the most
effective position.
Never use the RAIL SAW
without the safety guard or when
the 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 filter cleaning alarm)
Protective rubber case
TECHNICAL DETAILS:
frequency: 433 Mhz
max. distance: 5 metres
power: CR2032 Lithium cell battery
dimensions: 48x20xh107 mm
weight: 54 g
Item code: 6003788
The device supplied with the rail saw has 2 main functions:
- Switching off the machine: the main control for turning off the rail saw off is the
switch (18) on the machine itself. The machine can also be turned off with the auxiliary device
by simply moving towards it while pointing the device and pressing the STOP button
(1).
- Reset of the air 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.
– fully accelerate the machine for at least 10 seconds.
– replace the old battery (mod. CR2032) with a new one.
• Replacing the battery:
– Remove the rubber case by pulling it off from the aerial side.
– Press down on the rear compartment cover while sliding it in the direction of the arrow.
– Remove the dead battery and insert a new one, making sure it is the right way up.
– Replace the cover and the protective rubber case.
If it is expected that the device will not be used for a long time, it is advisable to remove the
battery in order to avoid damage caused by possible leaks and corrosion.
Batteries must be disposed of separately to other waste in accordance with local sta-
tutory requirements.
Aerial
Hook
Battery
compartment
Cover
REAR
VIEW

9
3.4) Abrasive cutting discs
For maximum performance, use the rail saw in conjunction with the high quality C-Rex range
Cembrediscs listed below, in compliance with the requirements of the standard EN 12413 for
bonded abrasives:
DISC
TYPE
Dimensions
diameter x thickness x hub
mm (inch)
(RPM)
Peripheral
speed
(m/s)
Compatibility
with 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 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.

10
4.1) Fuel mixture preparation
Risk of explosion or fire, petrol is extremely flammable, 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 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 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.

11
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
12
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 first 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 re-
fuelling 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

13
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
Thereferenceplate(5)isessentialforexactlylocating
the cutting line on the rail.
The length of the plate depends on the machine-
support arm assembly.
On the first cut it is necessary to establish an ori-
gin 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.
5
16
Fig. f
Wait until the disc has completely stopped before
mounting the machine on the support arm.
– Restart the engine (Fig.
f ).

14
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 ope-
rator 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
- Weight: 19.8 kg (43.5 lbs)
- Dimensions (mm):
h
S
ll h h l h
491 354
586
112 445
170
544
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
NOTE: if necessary, it is possible to use the rail
saw in manual mode with the AA-RDS sup-
port arm by the red lever (17) (Ref. to § 8.4).

15
Serial Number
Numéro de série
Seriennummer
Número de serie
Numero 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 firmly 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).
Ifthearmiswronglypositioned,itcancausecut-
ting which is not perfectly straight (Ref. Fig. c, d).
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
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 resumed
in a comfortable and precise manner. To carry out this opera-
tion, 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
1
1
1 - Rotate the blue lever (18) in order
to lock it in the external position, to
facilitatethisoperationitisadvisable
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
17
A
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) relea-
sing it so that it inserts into the
diametricallyoppositehole(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.
(B)
(A)
Sliding track
17
(C) 17
18
18
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
confirm that the operation has been performed
correctly.
NOTE:forpracticalreasons,werecommendtheinterface
unitisrotatedbeforeoverturning,inanycase 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 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.
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.
A
L

20
The figure shows the
correct positioning of
therail sawsupportedby
the arm on the two sides
of the rail, in stationary
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 firmly locked as described in § 6.1 and levers (17 and 18) are
completely inserted.
6
17
18
8
13