Wacker Neuson BTSSeries Operator'S Manual Download Page 3

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T00940GB

Important information

This machine has been provided with an EPA-certified engine.

Additional

information

can

found

the

engine

manufacturer‘s notes.

Engine exhaust, some of its constitvents, and certain vehicle

components contain or emit chemicals known to the State of

California to cause cancer and birth defects or other reproduc-

tive harm.

WARNING

Caution

This engine is an EPA engine.

Adjusting the engine speed will interfere with EPA certification and

the emissions.

Only authorized personnel can make adjustments to this engine.

Please contact you nearest engine dealer or your Wacker Dealer for more

information.

Summary of Contents for BTSSeries

Page 1: ...www wackergroup com Operator s Manual Gasoline portable cut off saw BTS 0109969en 001 10 2004 ...

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Page 3: ...n vehicle components contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproduc tive harm WARNING Caution This engine is an EPA engine Adjusting the engine speed will interfere with EPA certification and the emissions Only authorized personnel can make adjustments to this engine Please contact you nearest engine dealer or your Wacker Dealer for m...

Page 4: ...T00940GB 2 ...

Page 5: ...e of sale to the initial purchaser and continues for a period of 2 years PARTS COVERED Listed below are the parts covered by the Emission Components Defect Warranty Some of the parts listed below may require scheduled maintenance and are warranted up to the first scheduled replacement point for that part Fuel Metering System Carburetor and internal parts Fuel filter if applicable Throttle stopper ...

Page 6: ...ner you are responsible for the performance of the required maintenance listed in your owner s manual WACKER recommends that you retain all receipts covering maintenance on your engine but WACKER cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance As the engine owner you should however be aware that WACKER may deny warrant...

Page 7: ...HE USE OF PARTS THAT ARE NOT EQUIVALENT IN PERFORMANCE AND DURABILITY TO AUTHORIZED PARTS MAY IMPAIR THE EFFECTIVENESS OF THE EMISSION CONTROL SYSTEM AND MAY HAVE A BEARING ON THE OUTCOME OF A WARRANTY CLAIM If other than the parts authorized by WACKER are used for maintenance replacements or for the repair of components affecting emission control you should assure yourself that such parts are war...

Page 8: ...T00965GB 6 ...

Page 9: ... rights especially the right for copying and distribution are reserved Copyright by Wacker Construction Equipment AG No part of this publication may be reproduced in any form or by any means electronic or mechanical including photocopying without express permission in writing from Wacker Construction Equipment AG Any type of reproduction distribution or saving on data carriers of any type or metho...

Page 10: ...4 5 Putting into operation 18 4 6 Cutting blades 19 4 7 Kickback and lock in 22 4 8 Working behavior Method of working 23 4 9 Cutting metals 24 4 10 Cutting masonry concrete asbestos or asphalt 27 4 11 Transport and storage 29 4 12 Maintenance 30 4 13 First aid 31 5 Technical data 32 6 Denomination of components 34 7 Putting into operation 36 7 1 Fitting cutting blades 37 7 2 Tightening the V belt...

Page 11: ...air cleaner insert 50 8 5 Replacing the spark plug 51 8 6 Checking the ignition spark 52 8 7 Replacing the suction head 53 8 8 Starter rope replacement 53 8 9 Replace the return spring 55 8 10 Cutting arm in inboard outboard 56 8 11 Repositioning the cutting arm 57 8 12 Instructions for periodic maintenance 59 8 13 Troubleshooting 61 9 FBTS 62 9 1 Guide cart 62 9 2 Safety precautions 63 10 Labels ...

Page 12: ...le working even under very dusty conditions Two options for mounting the cutting arm Either inboard for good balance when guiding the unit manually outboard for flush cuts along walls or curbsides or horizontally directly above the ground Extensive range of accessories available such as resinoid bonded or diamond tipped cutting blades as well as a guide trolley water sprinkling system or angled fu...

Page 13: ...WACKER product T00961GB 11 2 1 Packing Your WACKER Power Cut is packed in a cardboard box to prevent shipping damage Cardboard is a basic raw material and is consequently reuseable or suitable for recycling waste paper recycling ...

Page 14: ...y inventory please consult your sales agent 3 2 Symbols You will notice the following symbols on the saw and in the operator s manual Read operator s manual and follow the warning and safety precautions Combination switch Start Stop I O choke 1 Cut off saw 3 Universal wrench 13 19 4 Allen key 5 Screwdriver for carburetor adjusment 6 Operator s manual not shown ...

Page 15: ...tion Wear protective helmet eye and ear protection Engine manual start Wear protective gloves Stop engine Wear respiratory protection Warning Kickback No smoking Fuel oil mixture No open fire First aid Turning direction of cutting blade Recycling Max peripheral blade speed CE marking Cutting blade dimensions ...

Page 16: ...n using cut off saws It is important to be familiar with the operation of this particular cut off saw Users insufficiently informed will endanger themselves as well as others due to improper handling 4 2 2 Let only persons who have experience in using cut off saws work with this unit When letting another person use the cut off saw this manual must be provided along with it 4 2 3 First time operato...

Page 17: ...llowing protective equipment must be used during operation of the cut off saw 4 3 2 The kind of clothing should be appropriate i e it should be tight fitting but not be a hindrance Clothing in which grains of material can accumulate trousers with cuffs jackets and trousers with wide open pockets etc must not be worn particularly when cutting metal 4 3 3 Do not wear any jewellery or clothing that c...

Page 18: ...oved respiratory protection E 4 3 8 Work gloves F of tough leather are part of the required work kit of the cut off saw and must always be worn when working with the cut off saw 4 3 9 Always wear safety shoes or boots G with steel toes non skid soles and leg protectors when working with the cut off saw Safety shoes equipped with a protective layer provide protection against cuts and ensure a secur...

Page 19: ...a spill occurs clean off the cutt off saw immediately Fuel should not come in contact with clothes If your clothes have come in contact with fuel change them at once 4 4 7 Ensure that no fuel runs into the soil environmental protection Use an appropriate base 4 4 8 Refuelling is not allowed in closed spaces Fuel vapors will accumulate near the floor explosion hazard 4 4 9 Make sure to firmly tight...

Page 20: ... Power Cut near inflammable materials or explosive gases The Power Cut can create sparks leading to fire or explosion 4 5 4 Make sure that all persons within 30 meters 100 feet such as other workers are wearing protective gear see Protective Equipment 8 Children and other unauthorized persons must remain more than 30 meters 100 feet away from the working area Keep an eye out for animals as well 9 ...

Page 21: ...pletely assembled 4 6 Cutting blades 4 6 1 The protective hood must always be on Change cutting blades only with the engine off Always make sure to observe the direction of rotation markings When using diamond cutting blades 4 6 2 Cutting blades have been designed exclusively for radial loads Never use the side face of the cutting blade for grinding purposes as there is danger of blade fracture AT...

Page 22: ...ighten the cutting blade s mounting bolt to a torque of 30 Nm 22 2ft lbs Otherwise the cutting blade could warp 4 6 7 Make sure you have a steady footing before starting the cutting blade 4 6 8 Put the cut off saw into operation only as described in this manual 13 Always place your left foot in the rear handle and grasp the other handle firmly with thumb and fingers Other starting methods are not ...

Page 23: ...ne 14 before checking the V belt s tension or retightening the V belt before replacing a cutting blade before changing the cutting arm inboard to outboard or vice versa and before eliminating malfunctions 4 6 17 Turn off the engine immediately and check the cutting blade if you hear or feel any change in cutting behaviour 4 6 18 Turn off the cut off saw when taking a break or stopping work 14 Plac...

Page 24: ...hown in figure 15 Be especially careful when reinserting the disc into cuts that have already been started 4 7 5 Lock in occurs when the cut narrows crack or workpiece under stress 4 7 6 This causes the cut off saw to suddenly jump forward out of control and with great force Risk of injury To prevent lock in observe the following 4 7 7 When reinserting the disc into previous cuts have the cut off ...

Page 25: ...r handles Never leave the cut off saw unattended 4 8 3 Whenever possible run the cut off saw at the rated arbour speed see Technical Data 4 8 4 Only use the cut off saw during good light and visibility periods Be aware of slippery or wet areas and of ice and snow risk of slipping 4 8 5 Never work on unstable surfaces Make sure that there are no obstacles in the working area risk of stumbling Alway...

Page 26: ... 4 8 13 When cutting workpieces down to length use a firm support If necessary secure the workpiece from slipping but do not steady it with your foot or allow another person to hold it 4 8 14 When cutting round items always secure them against rotation 4 8 15 When guiding the cut off saw by hand use the outboard position of the cutter arm only when actually necessary Otherwise always use the inboa...

Page 27: ...ade straight and vertical Do not tip it as this can break it 4 9 3 The best way to get a good clean cut is to pull or move the cut off saw back and forth Do not simply press the blade into the material 4 9 4 Thick round stock is best cut in stages 20 4 9 5 Thin tubing and pipes can be cut with a simple downward cut 4 9 6 Treat large diameter pipes as round stock To prevent tipping and for better c...

Page 28: ...TTENTION If there is a chance that the material is under stress be prepared for it to kick back Make sure you can get out of the way if you have to Be particularly careful in scrap metal yards junkyards at accident sites and with haphazard piles of material Precariously balanced pieces or pieces under stress can act in unpredictable ways and may slide jump out or burst Secure cutoff material from ...

Page 29: ...by cooling to improve visibility and to avoid excessive dust creation we strongly recommend wet cutting instead of dry cutting In wet cutting the blade is watered at an equal rate on both sides by a trickle of water WACKER offers the right accessories for all wet cutting applications see also SPECIAL ACCESSORIES 4 10 1 Remove foreign objects such as sand stones and nails found within the working a...

Page 30: ...d not cut through the entire material thickness creating unnecessary dust Instead simply make a shallow groove and then knock off the excess material cleanly on a flat surface 25 ATTENTION When cutting into lengths cutting through material making cutouts etc always make sure to plan the direction and sequence of cuts in such a way that the blade does not get jammed by the cut off piece and that no...

Page 31: ...utting blade before transporting the unit in a vehicle 4 11 6 The cut off saw should be stored safely in a dry place It must not be left outdoors Always dismount the cutting blade before storage Keep the cut off saw away from children 4 11 7 Before long term storage and before shipping the cut off saw follow the instructions in the chapter on Periodic care and maintenance ALWAYS empty the fuel tan...

Page 32: ...ectly 4 12 4 Clean the cut off saw regularly 4 12 5 Check the fuel tank cap regularly for good sealing Ovserve the accident prevention instructions issued by trade associations and insurance companies NEVER make any modifications to the cut off saw You will only be putting your own safety at risk Perform only the maintenance and repair works described in the operator s manual All other work must b...

Page 33: ...mation Place of the accident What happened Number of injured people Kind of injuries Your name NOTE Individuals with circulatory problems who are exposed to excessive vibration may experience injury to blood vessels or the nervous system Vibration may cause the following symptoms to occur in the fingers hands or wrists Falling asleep numbness tingling pain stabbing sensation alteration of skin col...

Page 34: ...sure level LpA eq per EN 1454 1 4 dB A 97 Sound power level LWA 109 db A Vibration acceleration ah w per EN 1454 Tubular handle idle rated spindle speed Rear handle idle rated spindle speed m s2 6 5 8 6 Carburetor diaphragm carburetor Typ Type TILLOTSON HS 273 A Ignition system with speed limitation Typ Type electronic Spark plug Typ Type NGK BPMR 7A BOSCH WSR 6F CHAMPION RCJ 6Y Electrode gap mm i...

Page 35: ...vel LpA eq per EN 1454 1 4 dB A 99 Sound power level LWA 110 db A Vibration acceleration ah w per EN 1454 Tubular handle idle rated spindle speed Rear handle idle rated spindle speed m s2 7 5 8 7 Carburetor diaphragm carburetor Typ Type TILLOTSON HS 273 A Ignition system with speed limitation Typ Type electronic Spark plug Typ Type NGK BPMR 7A BOSCH WSR 6F CHAMPION RCJ 6Y Electrode gap mm in 0 5 0...

Page 36: ...Denomination of components T00962GB 34 6 Denomination of components Identification plate Indicate when ordering spare parts ...

Page 37: ...ing screw 9 Retaining nuts 10 Base 11 Carburetor adjustment opening 12 Identification plate 13 Fuel tank with handle 14 Starter grip 15 Combination switch Start Stop I O choke 16 Stop knob for halfway throttle 17 Safety locking button 18 Throttle lever 19 Fuel tank plug 20 Fan housing with starting assembly 21 Cutting blade 22 Cutting blade fastening bolt 23 Spring washer 24 Lock bore for V belt p...

Page 38: ...t off saw Always wear protective gloves ATTENTIONE Start the cut off saw only after complete assembly and inspection For the the following work use the assembly tools included with delivery Place the cut off saw on a stable surface and carry out the following assembly steps 30 1 13 19 AF universal wrench 2 Allen key 3 Carburetor adjustment screwdriver 1 2 3 31 ...

Page 39: ...When using a diamond cutting disc be sure to mount it so that it rotates in the proper direction Place the spring washer 8 on the arbour and insert the screw 32 9 and tighten by hand Slowly turn the cutting disc until the stop hole of the V belt wheel is visible in the cutting arm hole 10 Insert the Allen key 2 as far as it will go The shaft is now blocked Tighten the screw with the combination wr...

Page 40: ... clutch bearing Retighten new V belt after first running hour NOTE The two fastening nuts 11 must be loosened before tightening the V belt or checking the tension To increase the belt tension turn the tightening screw 12 to the right clockwise with the combination wrench included with the cut off saw The belt tension is correctly adjusted when the nut 13 is centred on the mark 14 ATTENTION After t...

Page 41: ...e and two cycle engine oil The engine is designed for unleaded regular gasoline with a min octane value of 91 ROZ In case no such fuel is available you can use fuel with a higher octane value This will not affect the engine In order to obtain an optimum engine output and to protect your health and the environment use unleaded fuel only 36 Gasoline 50 1 1000 cm3 1 liter 20 cm3 5000 cm3 5 liter 100 ...

Page 42: ...hich will pollute the environment and clog the exhaust channel in the cylinder as well as the muffler In addition fuel consumption will rise and performance will decrease 7 4 Fuel storage Fuels have only a limited shelf life Buy only as much as you will use in 4 weeks Only store fuel in approved and marked containers AVOID SKIN AND EYE CONTACT Mineral oil products degrease your skin If your skin c...

Page 43: ... Carefully clean the area around the fuel tank filler neck to keep dirt from getting in the tank Place the unit on its side on an even surface Unscrew the tank cap and fill tank with fuel mixture Take care to avoid spilling Tightly screw on the plug Clean tank cap and surrounding area after refuelling Never start or operate the cut off saw in the same place as it was fuelled Fuel mixture 38 ...

Page 44: ...t away from the place where you fuelled the cut off saw Make sure you have a good footing and place the cut off saw on the ground in such a way that the cutting disc is not touching anything Turn protective hood 3 to optimum position according to cutting application see drawing Grab handle 2 and move protective hood 3 to any position desired between stops in either direction 39 if necessary 40 3 m...

Page 45: ...e lever lock 7 Push the throttle 8 in all the way and hold it Press the throttle lock 6 and release the throttle 8 the throttle lock will hold the throttle at half throttle position Grasp the tubular handle firmly with one hand and press the cut off saw firmly against the ground Place the tip of your left foot in the rear handle Slowly pull out the starter rope until you notice resistance the pist...

Page 46: ...ng except without moving the combination switch 42 5 to the choke position 7 9 Stopping the engine Push the combination switch 9 down to position 7 10 Adjusting the carburetor NOTE The cut off saw has been equipped with an electronic ignition to limit the speed The carburetor also has a fixed jet which cannot be adjusted At the factory the idling speed has been set to approx 2 500 1 min but the ru...

Page 47: ...t is warm about 3 5 minutes Carry out carburetor adjustment with the scope of delivery Readjusting the idle speed Proceed as follows if the cutting blade is turning while the engine is idling turn the throttle valve s stop screws 2 outwards until the cutting blade stops moving Turn the screw back in if the engine stops running while idling Stop engine 46 47 ...

Page 48: ...many of the parts and assemblies not mentioned in this Instruction Manual are vital to the safety of the unit and because all parts are subject to a certain amount of wear and tear it is important for your own safety that you have the unit checked and maintained regularly by a WACKER service station ATTENCION If the cutting blade should have broken during a cutting application take the cut off saw...

Page 49: ... cover 6 NOTE Screw 5 is longer than screws 7 Make sure to put them back in the right places during reassembly Loosen the screws 8 and remove the crankcase cover 9 Remove the old belt 10 or belt pieces Clean out the inside of the cutting arm with a brush Put in a new V belt NOTE Reassemble the crankcase housing cover 9 side cover 50 6 and cover 50 4 in the reverse order To tighten the V belt see T...

Page 50: ...from tim to time Take off the cutting blade with spring washer and remove the accumulated material from inside the hood with a strip of wood or similar implement Clean the shaft and all disassembled parts with a cloth 8 3 Cleaning changing the air filter Turn the cover lock 11 to the Unlocked position and carefully remover the filter cover 12 Two sealing rings 54 15 are located between the filter ...

Page 51: ... a small brush and check them for damage Remove prefilter 17 from the filter cover Pull air filter insert 18 from the hood Remove the inner filter 16 from the intake opening Note Do not allow dirt to get into the carburetor Set the combination switch to Choke or cover the carburetor with a clean cloth 54 55 ...

Page 52: ...lter 1 7 against a clean surface or wash in a luke warm soap sud of commercially available dish washer detergent Do not clean with fuel Let prefilter dry thoroughly The air cleaner insert 2 8 filters the intake air throughtan extremely fine paper filter lamellar system and should not be washed under any circumstances Open up the lamellas of the air cleaner insert slightly and carefully knock again...

Page 53: ...he insulator electrode erosion burn or if the electrodes are very dirty or oily ATTENCION Use only BOSCH WSR 6F spark plug CHAMPION RCJ 6Y or NGK BPMR 7A The use of a non approved spark plug may result in damage to the ignition system Turn the cover lock 6 to the Unlocked position and carefully remove the filter cover 7 Flip up spark plug cover 8 Pull plug cap 9 off spark plug Remove spark plug on...

Page 54: ...the spark plug hole but make contact only with the cylinder otherwise you may damage the engine Using insulated pliers hold the spark plug 10 unscrewed but with the plug cap on against the combination tool away from the spark plug hole Switch the combination switch 11 to I Pull the starter rope hard If the function is correct an ignition spark must be visible near the electrodes 58 ...

Page 55: ...and pull the loss prevention stopper out Empty fuel tank To remove the suction head for replacement pull it out through the tank filler neck using a piece of wire bent at one end to form a hook ATTENCION Do not allow fuel to come into contact with skin 8 8 Starter rope replacement Loosen four screws 14 Remove the fan housing 15 Unscrew 2 screws 16 and carefully remove air duct 17 from fan housing ...

Page 56: ...face of the rope drum Insert knot 22 into the starter handle 23 Guide the rope into the recess 24 on the rope drum and use the rope to turn the drum two turns in the direction shown by the arrow Holding the rope drum in your left hand straighten out the twist in the rope with your right hand pull the rope tight and hold Release the rope drum The drum s spring force will now wind the rope around th...

Page 57: ... fan housing it may be necessary to pull the starter rope lightly so that the rope pulley catches 8 9 Replace the return spring Take off fan housing see chapter Starter rope replacement Remove air duct from fan housing see chapter Starter rope replacement Remove retaining ring 1 see accessories for extemal retaining ring pliers Pull off rope drum 2 Unscrew screws 3 Carefully and evenly remove retu...

Page 58: ...rum slightly when placing until it snaps in audibly Mount retaining ring Coil starter rope see chapter starter rope replacement Assemble air duct see picture 62 If the need arises pull starter handle lightly until the starting device grips wehn replacing the fan housing 8 10 Cutting arm in inboard outboard NOTE The cut off saw is delivered with the cutting arm mounted in the inboard position 1 For...

Page 59: ... Unscrew the nuts 5 and remove the cover 6 Lift out stop bolt 7 with universal wrench 8 as shown in drawing until protective hood 10 can be turned NOTE The turning stop 65 7 is not active when the stop bolt 7 has been pulled The protective hood 10 can thus be turned further than normally allowed by the turning stop 65 7 Disengage V belt and then remove cutting arm 65 66 ...

Page 60: ...rd plate 15 on Screw on nuts 16 and tighten by hand To tighten the V belt see Tightening the V belt Checking V belt tension Tighten the nuts 16 firmly with the combination wrench ATTENCION When you reposition the cutting attachment the direction of rotation of the cutting wheel changes Diamond blacks must be filted according to the turning direction 67 68 ...

Page 61: ...re immediately Cutting blade Clutch Inspect regularly for damage and wear Protection hood Clean check position Before each start Cutting blade Check for damages and make sure the correct cutting blade for the planned aplication has been filted V belt Check V belt tension Combination switch Safety locking button Throttle lever Functional check Fuel tank plug Check for tightness Every day Prefilter ...

Page 62: ...63GB 60 Storage Entire cut off saw Clean exterior check for damage In case of damage have repaired by a qualified service centre immediately Cutting blade Remove and clean Fuel tank Empty and clean Carburetor Run empty ...

Page 63: ... dirty fuel line bent or interrupted Compres sion system Inside Cylinder base packing ring defective radial shaft packings defective cylinder or piston rings defective Outside Spark plug does not seal Mechanical malfunction Starter does not engage Spring in starter broken broken parts inside the engine Insufficient power Carburetor Fuel tank is filled Igntion spark Wrong carburetor adjustment Engi...

Page 64: ...inboard or outboard position For easier refuelling when using the trolley we recommend adding an angled tank filler neck The guide cart has been equipped with a water tank and a water spray system the water will bind the dust during the cutting process and will also help to cool the cutting disc Notches have been added to the area of the clamp lever thus making it easier to adjust the cutting dept...

Page 65: ... the cutting depth setting and the star shaped knob for the handle height setting are tightly screwed down during cutting applications 9 2 4 The guide cart should be cleaned with water after each use to avoid possible malfunctions 9 2 5 Park the equipment on an even horizontal surface during work breaks storage or transport Also make sure that the equipment has been secured against tipping over or...

Page 66: ...Labels SK00658GB 64 10 Labels 1 Fuel to oil ratio 2 Wacker Logo 3 Type 4 Cover safety 5 Protective hoad safety ...

Page 67: ...nstalled power has been evaluated in conformity with Directive 2000 14 EC and has been manufactured in accordance with the following directives 2000 14 EG 89 336 EG 98 37 EG BTS 930L3 BTS 935L3 BTS 1030L3 BTS 1035L3 0008340 0008341 0008987 0008988 0008339 0007975 0008912 0008989 0008990 3 2 kW 4 2 kW Conformity assessment procedure Measured sound power level Guaranteed sound power level BTS 930 93...

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Page 69: ...DIN EN ISO 9001 CERTIFICATE ...

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