Related Manuals for Wacker Neuson BTS Series
Summary of Contents for Wacker Neuson BTS Series
- Page 1 www.wackergroup.com 0109969en 10.2004 Gasoline portable cut-off saw BTS ... Operator´s Manual...
- Page 3 Important information This machine has been provided with an EPA-certified engine. Additional information found engine manufacturer‘s notes. WARNING 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.
- Page 4 T00940GB...
- Page 5 Warranty for machines equipped with an EPA-certified engine (USA) EMISSIONS COMPONENT DEFECT WARRANTY COVERAGE The engine manufacturer warrant(“s”) to the initial retail purchaser and each subsequent owner, that this non-road engine (herein “engine“) has been designed, built, and equipped to conform at the time of initial sale to all applicable regulations of the U.S.
- Page 6 WHAT IS NOT COVERED? ∗ Conditions resulting from tampering, misuse, improper adjustment (unless they were made by the service dealer authorized by WACKER during a warranty repair), alteration, accident, failure to use the recommended fuel and oil, or not performing required maintenance services.
- Page 7 MAINTENANCE AND REPAIRS You are responsible for the proper maintenance of the engine. You should keep all receipts and maintenance records covering the performance of regular maintenance in the event questions arise. These receipts and maintenance records should be transferred to each subsequent owner of the engine. WACKER reserves the right to deny warranty coverage if the engine has not been properly maintained.
- Page 8 T00965GB...
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Page 9: Foreword
Operating instructions Foreword For your own safety and protection from bodily injuries, carefully read, understand and follow the safety instructions in this manual. Please operate and maintain your Wacker machine in accordance with the instructions in this manual. Your Wacker machine will reward your attention by giving trouble-free operation and a high degree of availability. -
Page 10: Table Of Contents
Table Of Contents Foreword Thank you for purchasing a WACKER product! Packing ....................11 Delivery Inventory/Symbols Delivery Inventory ................12 Symbols ....................12 Safety precautions Use as designed ................. 14 General precautions ................14 Personal protective equipment ............15 Fuels/Refuelling .................. 17 Putting into operation ................. - Page 11 Table Of Contents Cold-starting ..................43 Warm-starting ..................44 Stopping the engine ................44 7.10 Adjusting the carburetor ..............44 Maintenance Changing the V-belt ................47 Cleaning the protective hood .............. 48 Cleaning/changing the air filter ............48 Prefilter and air cleaner insert ............50 Replacing the spark plug ..............
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Page 12: Thank You For Purchasing A Wacker Product
Thank you for purchasing a WACKER product! Thank you for purchasing a WACKER product! Congratulations on choosing a WACKER Power Cut cutoff saw! WACKER Portable Cut-off Saws feature specially designed high- performance engines with outstanding power-to-weight ratios, for heavy-duty yet lightweight tools. Other advantages of the WACKER Portable Cut-off Saws: ∗... -
Page 13: Packing
Thank you for purchasing a WACKER product! 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). T00961GB... -
Page 14: Delivery Inventory/Symbols
Delivery Inventory/Symbols Delivery Inventory/Symbols Delivery Inventory 1. Cut-off saw 3. Universal wrench 13/19 4. Allen key 5. Screwdriver for carburetor adjusment 6. Operator‘s manual (not shown) In case one of the parts listed should not be included in the delivery inventory, please consult your sales agent! Symbols You will notice the following symbols on the saw and in the operator´s... - Page 15 Delivery Inventory/Symbols Particular care and caution! Locked / Unlocked Forbidden! Use eye protection! Wear protective helmet, eye Engine - manual start and ear protection! Wear protective gloves! Stop engine! Wear respiratory protection! Warning! Kickback! No smoking! Fuel/oil mixture No open fire! First aid Turning direction of cutting Recycling...
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Page 16: Safety Precautions
Safety precautions Safety precautions Use as designed Cut-off saw The cut-off saw may only be used for the cutting/shortening of appropriate materials outdoors with a cutting blade approved for the machine Unauthorized working procedure The cutting blades of the cut-off saw may not be used for grinding purposes (removal of material with the side face of the cutting blade). -
Page 17: Personal Protective Equipment
Safety precautions 4.2.7 Never work while under the influence of alcohol, drugs, medication or other substances which may impair vision, dexterity or judgement. 4.2.8 Ar fire extinguisher must be available in the immediate vicinity when working in easily inflammable vegetation or when it has not rained for a long time (danger of fire). - Page 18 Safety precautions 4.3.6 To prevent hearing damage, always wear suitable personal hearing protection. (ear muffs (D), ear plugs, etc.). Octave brand analysis upon request. 4.3.7 When dry-cutting dust-producing materials such as stone or concrete, always wear approved 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...
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Page 19: Fuels/Refuelling
Safety precautions Fuels/Refuelling 4.4.1 Go to a safe, level place before refuelling. Never refuel while on scaffolding, on heaps of material, or in similar places! 4.4.2 Switch off the engine before refuelling the Power Cut. 4.4.3 Do not smoke or work near open fires (6). 4.4.4 Let the engine cool down before refuelling. -
Page 20: Putting Into Operation
Safety precautions 4.4.13 Use only approved and marked containers for the transport and storage of fuel. Keep fuel away from children! Putting into operation 4.5.1 Do not work on your own. There must be someone around in case of an emergency (within shouting distance). 4.5.2 Observe all anti-noise regulations when working in residential areas. -
Page 21: Cutting Blades
Safety precautions In particular, make sure that the cutting blade is in good conditions (replace immediately if torn, damaged or bent), the cutting blade is properly mounted, the protective hood is locked in place, the V-belt has the proper tension, the throttle moves easily and the half-throttle lock button functions properly, the handles are clean and dry, and the combination switch functions properly. - Page 22 Safety precautions 4.6.4 The arbour hole (bore) of the cutting blade must fit the shaft exactly. If the arbour hole is larger than the shaft diameter, a spacer ring must be used. 4.6.5 Free-hand cutting blades with a blade diameter of 355 mm (14“) must be approved for speeds of up to 4370 1/min (rpm) or80 m/s (260 ft./ sec);...
- Page 23 Safety precautions 4.6.11 When working with the cut-off saw always hold it with both hands. Take the back handle with the right hand and the tubular handle with the left hand. Hold the handles tightly with your thumbs facing your fingers. 4.6.12 ATTENTION: When you release the throttle lever the cutting blade will keep spinning for a short period of time (free-wheeling effect.).
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Page 24: Kickback And Lock-In
Safety precautions Kickback and lock-in 4.7.1 There is a danger of kickback and lock-in. When working with the cut- off saw. 4.7.2 Kickback occurs when the top of the cutting blade is used for cutting (15). 4.7.3 This causes the cut-off saw to be thrown back toward the user with great force and out of control. -
Page 25: Working Behavior/Method Of Working
Safety precautions 4.7.9 When starting a cut, apply the cutting blade to the workpiece with care. Do not just shove it into the material. 4.7.10 Never cut more than one piece at a time! When cutting, make sure that no other workpiece is touched. Working behavior/Method of working 4.8.1 Before starting work, check the work area for any hazards (electrical... -
Page 26: Cutting Metals
Safety precautions 4.8.10 Guide the cut-off saw in such a way that no part of your body is within the extended swing range of the blade (18). 4.8.11 Use cutting blades only for the materials for which they are designed! 4.8.12 Do not use the cut-off saw to lift up and shovel away pieces of material and other objects. - Page 27 Safety precautions CAUTION! The rapid rotation of the cutting blade heats metal and melts it at the point of contact. Swing the guard as far down as possible behind the cut (19) in order to direct the stream of sparks forward, away from the operator (fire hazard).
- Page 28 Safety precautions 4.9.8 Cut I-beams and L-bars in steps; see Figure 21. 4.9.9 Cut bands and plates like pipes: along the wide side with a long cut. 4.9.10 When cutting material under stress (supported material or material in structures), always make a notch in the thrust (pressure) side, and then cut from the tension side, so that the blade does not lock in (22).
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Page 29: Cutting Masonry Concrete, Asbestos Or Asphalt
Safety precautions 4.10 Cutting masonry concrete, asbestos or asphalt ATTENTION! Always wear approved respiratory protection! Asbestos and other materials that can release toxic substances may be cut only after notifying the proper authorities and under their supervision or that of a person appointed by them. When cutting prestressed and reinforced concrete piles, follow the instructions and standards of the responsible authorities or the builder of the structural member. - Page 30 Safety precautions NOTE: For long, straight cuts we recommend using a guide cart (24, see also “SPECIAL ACCESSORIES“). This makes it much easier to guide the unit in a straight line with less effort. 4.10.3 When cutting slabs to size, you need not cut through the entire material thickness (creating unnecessary dust).
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Page 31: Transport And Storage
Safety precautions 4.11 Transport and storage 4.11.1 Always turn off the cut-off saw when transporting it or moving it from place to place on a site (26). 4.11.2 Never carry or move the unit with the engine running or the blade turning! 4.11.3 Carry the unit only by the tubular (middle) handle with the cutting blade pointing behind you (26). -
Page 32: Maintenance
Safety precautions 4.12 Maintenance 4.12.1 Switch off the cut-off saw (27) and pull out the plug cap Before performing maintenance work. 4.12.2 Always check the cut-off saw before using it to make sure that it is in good working order. In particular, make sure that the cutting blade is properly mounted. -
Page 33: First Aid
Safety precautions 4.13 First aid For the event of a possible accident, please make sure that a first aid kit is always immediately available close by. Immediately replace any items used from the first aid box. When calling for help, give the following information: ∗... -
Page 34: Technical Data
Technical data Technical data BTS 930L3 BTS 935L3 Item no. 0008987 ... 0008988 ... Displacement (cu in) 64 (3,9) Bore mm (in) 47 (1,85) Stroke mm (in) 37 (1,46) Max. power kW (hp) 3,3 (4,5) Max. torque Nm (ft.lbs.) 4,0 (3,0) Idling speed 1/min [rpm] 2.500... - Page 35 Technical data BTS 1030L3 BTS 1035L3 Item no. 0008989 ... 0008990 ... Displacement (cu in) 73 (4,5) Bore mm (in) 50 (1,97) Stroke mm (in) 37 (1,46) Max. power kW (hp) 4,2 (5,7) Max. torque Nm (ft.lbs.) 5,0 (3,7) Idling speed 1/min [rpm] 2.500 Clutch engagement speed...
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Page 36: Denomination Of Components
Denomination of components Denomination of components Identification plate Indicate when ordering spare parts! T00962GB... - Page 37 Denomination of components 1 Handle 2 Filter cover for air filter and spark plug cap 3 Cover lock 4 Tubular handle 5 Muffler 6 Protective hood 7 Protective hood handle 8 V-belt tension adjusting screw 9 Retaining nuts 10 Base 11 Carburetor adjustment opening 12 Identification plate 13 Fuel tank with handle...
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Page 38: Putting Into Operation
Putting into operation Putting into operation ATTENTION: Always turn off the engine and pull off the spark plug cap before doing any work on the cut-off saw! Always wear protective gloves! ATTENTIONE: Start the cut-off saw only after complete assembly and inspection. -
Page 39: Fitting Cutting Blades
Putting into operation Fitting cutting blades Model Inspect disc damage, SAFETY INSTRUCTIONS. Unscrew screw (9) and remove the spring washer (8). Place the cutting disc (5) on the arbour (7). NOTE: The arbor hole of the cutting disk must fit the shaft precisely. Use an adapter ring to compensate for a larger arbor hole. -
Page 40: Tightening The V-Belt/Checking V-Belt Tension
Putting into operation Tightening the V-belt/Checking V-belt tension ATTENTION: Exact V-belt tension is essential for maximum cutting performance with minimum fuel consumption. Improper V-belt tension will result in premature wear to the V-belt and V-belt pulley or damage to the 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. -
Page 41: Fuels
Putting into operation Fuels ATTENTION: The cut-off saw uses mineral-oil products (gasoline and oil). Be especially careful when handling gasoline. Do not smoke. Do not allow gasoline to come near flames, sparks or fire (explosion hazard). Gasoline 50:1 1000 cm (1 liter) 20 cm 5000 cm... -
Page 42: Fuel Storage
Putting into operation The 2-cycle engine oil must comply with API TC, JASO FC or ISO L- EGD specifications. NOTE: For preparing the fuel-oil mixture first mix the entire oil quantity with half of the fuel required, then add the remaining fuel. Shake the finished mixture thoroughly before pouring it into the saw‘s tank. -
Page 43: Refuelling
Putting into operation Refuelling Fuel mixture ATTENCION: FOLLOW THE SAFETY PRECAUTIONS BY ALL MEANS! Be careful and cautious when handling fuels. The engine must be turned off and cooled down! Carefully clean the area around the fuel-tank filler neck to keep dirt from getting in the tank. -
Page 44: Starting The Engine
Putting into operation Starting the engine necessary 3 meters (10 feet) ATTENCION: Observe the SAFETY INSTRUCTIONS under all circumstances! Start the cut-off saw only after complete assembly and inspection! Move at least 3 m (10feet) away from the place where you fuelled the cut-off saw. -
Page 45: Cold-Starting
Putting into operation ATTENCION: By all means make sure that outer edge of stop plate (4) is parallel to the edge of the protective hood (see arrows). Visit a specialized work shop if this should not be the case. Cold-starting Move the combination switch (5) upwards (choke position). -
Page 46: Warm-Starting
Putting into operation ATTENCION: Do not pull out the starter rope more than approx. 50 cm (20 feet), and lead it back by hand. Move the combination switch (42/5) to the position “I“. Keep pulling the starter rope until the engine starts running. As soon as the engine is running, press the throttle (42/8) to release the half-throttle lock (42/6), allowing the engine to idle. - Page 47 Putting into operation The following steps must be carried out: For the correct adjustment of the idling speed Start the engine and run it until it 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...
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Page 48: Maintenance
Maintenance Maintenance ATTENCION Before doing any work on the cut-off saw turn off the engine, remove the cutting blade, pull the plug cap off the spark plug and wear protective gloves! ATTENCION Start the cut-off saw only after complete assembly and inspection. -
Page 49: Changing The V-Belt
Maintenance Changing the V-belt Loosen nuts (3). Loosen the tightening screw (1) (counter-clockwise) until the end of the screw (2) is visible in the gap. Unscrew the nuts (3) and remove the cover (4). Remove the screws (5) and (7) and remove the side cover (6). NOTE: Screw (5) is longer than screws (7). -
Page 50: Cleaning The Protective Hood
Maintenance Cleaning the protective hood NOTE: See “Fitting cutting blades“ for assembly of blades. Over time, the inside of the protective hood can become caked with material residue (especially from wet cutting), which if allowed to accumulate can hinder the free rotation of the cutting blade. For this reason the hood must be cleaned out from tim to time. - Page 51 Maintenance Loosen the screws (13) and remove the covering cap (14). Clean the sealing rings (15) with 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.
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Page 52: Prefilter And Air Cleaner Insert
Maintenance Prefilter and air cleaner insert Service-notes: Clean prefilter (1/7) daily ore more often if in the pesence of a lot of dust. Replace latest after 20 hours running time! Clean air cleaner insert (2/8) once every week, replace every 100 hours running time! This means that with proper maintenance the air cleaner insert needs be replaced after the prefilter has been replaced five times. -
Page 53: Replacing The Spark Plug
Maintenance Replacing the spark plug ATTENCION: Do not touch the spark plug or plug cap if the engine is running (high voltage). Switch off the engine before starting any maintenance work. A hot engine can cause burns. Wear protective gloves! The spark plug must be replaced in case of damage to the insulator, electrode erosion (burn) or if the electrodes are very dirty or oily. -
Page 54: Checking The Ignition Spark
Maintenance Checking the ignition spark Insert the combination wrench (9) between the hood and cylinder only as shown. ATTENCION! Do not insert the combination tool into 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!). -
Page 55: Replacing The Suction Head
Maintenance Replacing the suction head The felt filter (13) of the suction head can become clogged. It is recommended to replace the suction head once every three months in order to ensure unimpeded fuel flow to the carburetor. Unscrew the fuel tank cap (12) and pull the loss-prevention stopper out. - Page 56 Maintenance Thread a new 1000 mm (40“) long and 4,0 mm (0,16“) diameter starter rope as shown in the drawing (do not forget washer (19) and then tie knots at both ends. Pull knot (20) into rope drum (21). ATTENCION: The knot or, as the case may be, the end of the rope should not jut out over the surface of the rope drum.
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Page 57: Replace The Return Spring
Maintenance NOTE: With the rope pulled all the way out, it must still be possible to turn the pulley another 1/4 turn against the return spring. ATTENCION! Injury hazard! When you pull out the starter rope hold the starter handle firmly. It will whip back if the rope drum is released by accident. -
Page 58: Cutting Arm In Inboard/Outboard
Maintenance Replacement retum springs are delivered inside a housing and pretensed. CAUTION, the spring can jump out. A spring that has jumped out can be placed back in the housing by following the drawing (pay attention to the direction of rotation!). The new return spring (4) must be lightly greased with multipurpose grease before proceeding with mounting inside the fan housing. -
Page 59: Repositioning The Cutting Arm
Maintenance 8.11 Repositioning the cutting arm Loosen nuts (5). Loosen the tightening screw (3) (counter-clockwise) until the end of the screw (4) is visible in the gap. 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. - Page 60 Maintenance Press the cutting arm (12) in the side position onto the drive arm attachment. Guide the V-belt (13) over the V-belt wheel (14). Put the guard 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“.
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Page 61: Instructions For Periodic Maintenance
Maintenance 8.12 Instructions for periodic maintenance To ensure long life, prevent damage and ensure the full functioning of the safety features the following maintenance must be performed regularly. Warranty claims can be recognized only if this work is performed regularly and properly. Failure to perform the prescribed maintenance work can lead to accidents! Users of the cut-off saw must not perform any maintenance work not described in this Instruction Manual. - Page 62 Maintenance 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. T00963GB...
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Page 63: Troubleshooting
Maintenance 8.13 Troubleshooting Malfunction System Observation Cause Cutting blade Clutch Engine runs Damage to clutch does not start turning Cutting blade Carburetor, Cutting blade Incorrect idle speed, clutch turns while Clutch turns stuck engine idles Engine does Ignition Ignition spark Malfunction in fuel supply not start or only system... -
Page 64: Fbts
FBTS FBTS Guide cart The WACKER guide cart makes it much easier to carry out straight cuts, while simultaneously enabling almost untiring working. It can be adjusted for the operator‘s height, and can be operated with the cutting arm mounted in the inboard or outboard position. For easier refuelling when using the trolley, we recommend adding an angled tank filler neck. -
Page 65: Safety Precautions
FBTS Safety precautions 9.2.1 The mounting brackets for the cut-off saw must be cleaned before placing the BTS into the guide cart. 9.2.2 The stop bolt must be correctly engaged to avoid a possible detaching of the cut-off sawduring applications. 9.2.3 Be careful to verify that both the clamp lever for the cutting depth setting and the star-shaped knob for the handle height setting are... -
Page 66: Labels
Labels 10. Labels Fuel to oil ratio Wacker Logo Type Cover safety Protective hoad safety SK00658GB... -
Page 67: Ec - Confornity Certificate
EC - Confornity Certificate Wacker Construction Equipment AG , Preußenstraße 41, 80809 München hereby certify that the construction equipment specified hereunder: 1. Category: Portable gasoline cut-off saw 2. Type: BTS 930L3 / BTS 935L3 BTS 1030L3 / BTS 1035L3 3. Equipment item number: 0008340 ... -
Page 69: Din En Iso 9001 Certificate
DIN EN ISO 9001 CERTIFICATE...