Gasoline Portable Cut-off Saw

Transcript

www.wackergroup.com 0109969en 10.2004 001 Gasoline portable cut-off saw BTS ... Operator´s Manual Important information This machine has been provided with an EPA-certified engine. Additional information manufacturer‘s notes. can be found in the engine 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 reproductive harm. 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. T00940GB 1 T00940GB 2 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. Environmental Protection Agency (EPA), and that the engine is free of defects in materials and workmanship which would cause this engine to fail to conform with EPA regulations during its warranty period. For the components listed under PARTS COVERED, the service dealer authorized by WACKER will, at no cost to you, make the necessary diagnosis, repair, or replacement necessary to ensure that the engine complies with applicable U.S. EPA regulations. EMISSISON COMPONENT DEFECT WARRANTY PERIOD The warranty period for this engine begins on the date 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, if applicable Choke System, if applicable Air Induction System Air cleaner plate, Air filter Air cleaner case, Intake manifold Ignition System Spark plugs Flywheel Magneto Ignition Coil Miscellaneous Items Used in Above Systems Fuel hoses, clamps and sealing gaskets OBTAINING WARRANTY SERVICE To obtain warranty service, take your engine to the nearest authorized WACKER service dealer. Bring your sales receipts indicating date of purchase for this engine. The service dealer authorized by WACKER will perform the necessary repairs or adjustments within a reasonable amount of time and furnish you with a copy of the repair order. All parts and accessories replaced under this warranty become the property of WACKER. T00965GB 3 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. ∗ The replacement parts used for required maintenance services. ∗ Consequential damages such as loss of time, inconvenience, loss of use of the engine or equipment, etc. ∗ Diagnosis and inspection charges that do not result in warranty-eligible service being performed. ∗ Any non-authorized replacement part, or malfunction of authorized parts due to use of non-authorized parts. OWNER’S WARRANTY RESPONSIBILITIES As the engine owner, 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 warranty coverage if your engine or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications. You are responsible for presenting your engine to the nearest service dealer authorized by WACKER when a problem exists. If you have any questions regarding your warranty rights and responsibilities, you should contact the WACKER CORPORATION Product Support Department (U.S.A. 1800-770-0957, Canada 1-877-977-0775) for the information. THINGS YOU SHOULD KNOW ABOUT THE EMISSION CONTROL SYSTEM WARRANTY: T00965GB 4 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. Warranty claims will not be denied, however, solely because of the lack of required maintenance or failure to keep maintenance records. MAINTENANCE, REPLACEMENT OR REPAIR OF EMISSION CONTROL DEVICES AND SYSTEMS MAY BE PERFORMED BY ANY REPAIR ESTABLISHMENT OR INDIVIDUAL; HOWEVER, WARRANTY REPAIRS MUST BE PERFORMED BY A SERVICE DEALER AUTHORIZED BY WACKER. THE 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 warranted by their manufacturer to be equivalent to the parts authorized by WACKER in their performance and durability. HOW TO MAKE A CLAIM All repair qualifying under this limited warranty must be performed by a service dealer authorized by WACKER. In the event that any emission-related part is found to be defective during the warranty period, you shall notify WACKER CORPORATION Product Support Department (U.S.A. 1-800-770-0957, Canada 1-877-977-0775) and you will be advised of the appropriate warranty service dealer or service providers where the warranty repair can be performed. T00965GB 5 T00965GB 6 Operating instructions 1. 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. Defective machine parts are to be replaced as soon as possible. All 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 method not authorized by Wacker represents an infringement of valid copyrights and will be prosecuted. We expressly reserve the right to technical modifications - even without express due notice - which aim at improving our machines or their safety standards. 7 Table Of Contents 1. Foreword 2. Thank you for purchasing a WACKER product! 2.1 3. 12 Delivery Inventory ............................................................................... 12 Symbols .............................................................................................. 12 Safety precautions 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12 4.13 10 Packing ............................................................................................... 11 Delivery Inventory/Symbols 3.1 3.2 4. 7 14 Use as designed ................................................................................. 14 General precautions ........................................................................... 14 Personal protective equipment ........................................................... 15 Fuels/Refuelling .................................................................................. 17 Putting into operation ......................................................................... 18 Cutting blades .................................................................................... 19 Kickback and lock-in ........................................................................... 22 Working behavior/Method of working ................................................. 23 Cutting metals .................................................................................... 24 Cutting masonry concrete, asbestos or asphalt ................................. 27 Transport and storage ........................................................................ 29 Maintenance ....................................................................................... 30 First aid ............................................................................................... 31 5. Technical data 32 6. Denomination of components 34 7. Putting into operation 36 7.1 7.2 7.3 7.4 7.5 7.6 Fitting cutting blades .......................................................................... 37 Tightening the V-belt/Checking V-belt tension ................................... 38 Fuels ................................................................................................... 39 Fuel storage ....................................................................................... 40 Refuelling ........................................................................................... 41 Starting the engine ............................................................................. 42 8 Table Of Contents 7.7 7.8 7.9 7.10 8. Maintenance 8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8 8.9 8.10 8.11 8.12 8.13 9. Cold-starting ....................................................................................... 43 Warm-starting ..................................................................................... 44 Stopping the engine ........................................................................... 44 Adjusting the carburetor ..................................................................... 44 46 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 .................................................................... 51 Checking the ignition spark ................................................................ 52 Replacing the suction head ................................................................ 53 Starter rope replacement .................................................................... 53 Replace the return spring ................................................................... 55 Cutting arm in inboard/outboard ......................................................... 56 Repositioning the cutting arm ............................................................. 57 Instructions for periodic maintenance ................................................. 59 Troubleshooting .................................................................................. 61 FBTS 9.1 9.2 62 Guide cart ........................................................................................... 62 Safety precautions .............................................................................. 63 10. Labels 64 EC - Confornity Certificate 65 DIN EN ISO 9001 CERTIFICATE 67 9 Thank you for purchasing a WACKER product! 2. Thank you for purchasing a WACKER product! Congratulations on choosing a WACKER Power Cut cutoff saw! WACKER Portable Cut-off Saws feature specially designed highperformance engines with outstanding power-to-weight ratios, for heavy-duty yet lightweight tools. Other advantages of the WACKER Portable Cut-off Saws: ∗ Sturdy construction and high reliability. ∗ Maintenance-free electronic ignition, hermetically sealed to protect against dust and moisture. ∗ Vibration damping with 2-mass system for Less fatigue-oróne working even when guiding the Cut-off Saw by hand. ∗ Five-stage air-filter system for reliable 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 fuel tank filler neck. We want you to be satisfied with your WACKER product. In order to guarantee the optimal function and performance of your Cut-off Saw and to ensure your personal safety we would request you to perform the following: Read this instruction manual carefully before putting the Cut-off Saw into operation for the first time, and strictly observe the safety regulations! Failure to observe these precautions can lead to severe injury or death T00961GB 10 Thank you for purchasing a WACKER product! 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). T00961GB 11 Delivery Inventory/Symbols 3. Delivery Inventory/Symbols 3.1 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! 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! T00961GB 12 Combination switch Start/Stop (I/O), choke Delivery Inventory/Symbols Particular care and caution! Locked / Unlocked Forbidden! Use eye protection! 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 T00961GB 13 Safety precautions 4. Safety precautions 4.1 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). This could cause the blade to fracture! Fitting the cut-off saw with circular saw discs, knives, brushes etc. is absolutely forbidden. Non-authorized operators: Persons who are not familiar with the operator´s manual, children, teenagers, as well as persons under the influence of alcohol, drugs or medication are not allowed to operate the machine. 4.2 General precautions 4.2.1 The operator MUST read this manual to ensure safe operation (even if you already have experience in 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. 1 SV00068GB 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 operators should ask a specialist to instruct them in working with gasoline-powered cut-off saws. 4.2.4 Children and persons under 18 years of age must not be allowed to use this cut-off saw. Persons over the age of 16 years may, however, use the cut-off saw for the purpose of being trained as long as they are under the supervision of a qualified trainer. 4.2.5 Working with the cut-off sawrequires high concentration. 4.2.6 Operate the Power Cut only if you are in good physical condition. If you are tired, your attention will be reduced. Be especially careful at the end of a working day. Perform all work calmly and carefully. The user has to accept liability for others. 14 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. 2 4.3 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). 4.2.9 Asbestos and other materials that can release toxins may be cut only with the necessary safety precautions and after notification of the proper authorities and under their supervision or that of a person appointed by them. Personal protective equipment 4.3.1 In order to avoid head, eye, hand or foot injuries as well as to protect your hearing the following 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 can get caught or distract from the operation of the cut-off saw. 3 SV00068GB 4.3.4 It is necessary to wear a protective helmet whenever working with the cut-off saw. The protective helmet (A) is to be checked in regular intervals for damage and is to be replaced after 5 years at the latest. Use only approved protective helmets. 4.3.5 The helmet visor (B) protects the face from dust and material grains. In order to prevent injuries to eyes and face, always wear protective goggles (C) or visor when using the cut-off saw. 15 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 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 saw. 5 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 secure footing. 4.3.10 SV00068GB Always wear a work suit (H) of sturdy material. 16 Safety precautions 4.4 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. 6 4.4.3 Do not smoke or work near open fires (6). 4.4.4 Let the engine cool down before refuelling. 4.4.5 Fuels can contain substances similar to solvents. Eyes and skin should not come in contact with mineral oil products. Always wear protective gloves when refuelling (not the regular work gloves!). Frequently clean and change protective clothes. Do not breathe in fuel vapors. Inhalation of fuel vapours can be hazardous to your health. 4.4.6 Do not spill fuel. If 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 tighten the screw plug of the fuel tank. 3 meters (10 feet) 7 SV00068GB 4.4.10 Before starting the engine, move to a location at least 3 meters (10 feet) from where you fuelled the cut-off saw (7), but not within the extended swing range of the cutting blades (direction of sparks). 4.4.11 Fuel cannot be stored for an unlimited period of time. Buy only as much as will be consumed in the near future. 4.4.12 When making up the gasoline/oil mixture, always put the oil in the mixing container first, and then the gasoline. 17 Safety precautions 4.4.13 Use only approved and marked containers for the transport and storage of fuel. Keep fuel away from children! 4.5 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. 4.5.3 Never use the Power Cut near inflammable materials or explosive gases! The Power Cut can create sparks leading to fire or explosion! 30 m(100 feet) = Wear protective equipment 8 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). 9 4.5.5 SV00068GB Before starting work the cut-off saw must be checked for perfect function and operating safety in aaccordance with regulations. 18 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. 4.5.6 4.6 Start the cut-off saw only after complete assembly and inspection. Never use the cutt-off saw when it is not completely assembled. 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. 10 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. min. 5 m (16 feet) 11 ATTENTION! Never change direction (turning radius less than 5 meters (16 feet), exert lateral (sideways) pressure, or cant the cut-off saw during cutting applications (11)! 4.6.3 SV00068GB Use a cutting blade only for cutting the materials it is intended for. The proper type of blade must be selected for either metals or concrete. 19 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); blades with a blade diameter of 300 mm (12“) must be approved for speeds of up 5100 1/min (rpm) or 80 m/s (260 ft./sec). 12 4.6.6 The cutting blade must be free of defects (12). Make sure by sound testing with a piece of wood. Do not use defective cutting discs. Always tighten 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. 13 SV00068GB 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 allowed. 4.6.9 When starting the cut-off saw it must be well supported and securely held. The cutting blade must not be touching anything. 4.6.10 If the cutting blade is new, test it by running it at least 60 seconds at top speed. When doing this, make sure that no persons or body parts are in the extended swing range of the cutting blade, in case it is defective and flies apart. 20 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.). 4.6.13 Always make sure that you have a safe footing. 4.6.14 Hold the cut-off saw such that you will not breathe in the exhaust gas. Do not work in closed rooms or in deep holes or ditches (danger of poisoning by fumes). 4.6.15 Immediately switch off the cut-off saw if you observe any changes in its operating behavior. *Maintenance *Refuelling *Replacing the cutting blade *Repositioning *Work the cutting arm pause *Transport *Out 14 of operation 4.6.16 Stop the engine (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). Place the unit in such a way that the cutting blade is not touching anything and cannot endanger anyone. 4.6.19 Do not put the overheated cut-off saw in dry grass or on any inflammable objects. The muffler is very hot (danger of fire). 4.6.20 ATTENTION: After wet cutting, first turn off the water feed and then let the blade run at least another 30 seconds, to fling off the remaining water and prevent corrosion. SV00068GB 21 Safety precautions 4.7 Kickback and lock-in 4.7.1 There is a danger of kickback and lock-in. When working with the cutoff saw. 15 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. Risk of injury! To prevent kickback, observe the following: 4.7.4 Never cut with the section of the cutting blade shown 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 saw running at top speed. Always cut at top speed. 16 4.7.8 SV00068GB Always support the workpiece so that the cut is under pulling tension (16), so that the cut does not press together and jam the cutting blade as it proceeds through the material. 22 Safety precautions 4.8 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 wires, inflammable substances). Clearly mark the work area (for example with warning signs or by cordoning off the area). 4.8.2 When working with the cut-off saw hold it firmly by the front and rear 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. Always ensure that you have a safe footing. 17 SV00068GB 4.8.6 Never cut above your shoulder height (17). 4.8.7 Never stand on a ladder to cut (17). 4.8.8 Never use the cut-off saw while standing on scaffolding. 4.8.9 Do not lean over too far when working. When putting down and picking up the cut-off saw, do not bend over from the waist, but instead bend in the knees. Save your back! 23 Safety precautions 18 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. Important injury hazard! Before cutting, remove all foreign objects, such as rocks, gravel, nails etc. from the cutting area. Otherwise, such objects can be flung away by the blade with great speed. 4.9 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 inboard position. This gives the unit a better balance, for reduced operator fatigue. Cutting metals ATTENTION! Always wear approved respiratory protection! 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. SV00068GB 24 Safety precautions 19 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). 4.9.1 Determine the direction of cutting, mark the cut and apply the blade to the material at moderate speed, to cut a guide groove before going to top speed and applying more pressure to the cut-off saw. 4.9.2 Keep the blade 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. 20 SV00068GB 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 control, do not let the blade sink too deeply into the material. Instead, always cut shallow around the whole piece. 4.9.7 Worn blades have a smaller diameter than new blades, so that at the same engine speed they have a lower effective circumferential speed and therefore do not cut as well. 25 Safety precautions 21 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. 22 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). Secure cutoff material from falling! ATTENTION! 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 falling (22)! Always exercise extreme caution and use only equipment that is in perfect working order. Observe the accident-prevention rules and regulations of your employer and/or insurance organization. SV00068GB 26 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. Reinforcement rods must be cut in the prescribed sequence and in accordance with applicable safety regulations. NOTE! Mortar, stone, and concrete develop large quantities of dust during cutting. To increase the lifetime of the cutting blade (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 area. Caution: Watch out for electric wires and cables! 23 The rapid rotation of the cutting blade at the point of contact throws fragments out of the cut groove at high speed. For your safety, swing the protective hood down as far as possible behind the cut (23), so that material fragments are thrown forward, away from the operator. 4.10.2 SV00068GB Mark the cut, and then make a groove about 5 mm deep (just under 0,2“) along the entire length of the planned cut. This groove will then guide the cut-off saw accurately guring the actual cutoff. 27 Safety precautions 24 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. 25 4.10.3 When cutting slabs to size, you need 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 persons can be injured by falling pieces. SV00068GB 28 Safety precautions 4.11 Transport and storage 26 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). Avoid touching the exhaust muffler (burn hazard!). 4.11.4 When moving the cut-off saw over longer distances, use a wheelbarrow or wagon. 4.11.5 When transporting the cut-off saw in a vehicle, make sure it is securely positioned in such a way that no fuel can leak out. Always remove the cutting 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 tank and run the carburetor dry. 4.11.8 When putting cutting bladess in storage, be careful to: 4.11.9 Clean and dry them well. 4.11.10 Store them lying down flat. 4.11.11 Avoid dampness, freezing temperatures, direct sunshine, high temperatures and temperature fluctuations, as these can cause breakage and splintering. 4.11.12 Always check new cutting blades or blades that have been in storage to make sure that they are free of defects. SV00068GB 29 Safety precautions 4.12 Maintenance 27 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. Make sure that the cutting blade is undamaged and suitable for the job it will be used for. 4.12.3 Operate the cut-off saw only at a low noise and emission level. For this ensure the carburetor is adjusted correctly. 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! SERVICE 28 Perform only the maintenance and repair works described in the operator‘s manual. All other work must be carried out by WACKER Service. Use only original WACKER spares and accessories. The use of non-WACKER spares, accessories, or cutting blades increases the risk of accident. We cannot accept any responsibility for accidents or damage occurring in association with the use of accesories other than original WACKER. SV00068GB 30 Safety precautions 4.13 First aid 29 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: ∗ 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 colour or of the skin. If any of these symptoms occur, see a physician! SV00068GB 31 Technical data 5. Technical data Item no. cm3 Displacement BTS 930L3 BTS 935L3 0008987 ... 0008988 ... (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 Clutch engagement speed 1/min [rpm] 3.800 Engine speed limitation 1/min [rpm] 9.350 shaft speed 1/min [rpm] 4.300 Sound pressure 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 (in) 0,5 (.020) Fuel consumption at max. load per ISO 8893 l/h (US qt/h) 2,1 (2,2) Specific consumption at max. load per ISO 8893 g/kWh (oz./hph) 500 (13) Fuel tank capacity l (US qt) 1,1 (1,2) 50:1 Mixture ratio fuel/two-stroke oil 5) Cutting blade fer max. 80 m/s (260 ft/sec.) 2) mm (in) 300 / 20,0 / 53) (12/0,787/0,2) 350 / 25,4 / 53) (14/1/0,2) Arbor diameter mm (in) 20,0 (0,787“) 25,4 (1“) 10,0 (22) 10,2 (22,5) Weight cut-off saw (empty tank, no blade) 1 kg (lb) ) Figures derived in equal part from idle and max.-speed operation. ) Circumference speed at max. engine speed. 3 ) Outside diameter/arbor hole/thickness. 4 ) At the workplace (at user‘s ear). 5 ) With 2-cycle engine oil according to API TC, JASO FC. or ISO L-EGD 2 TD00676GB 32 Technical data Item no. BTS 1030L3 BTS 1035L3 0008989 ... 0008990 ... cm3 (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 1/min [rpm] 3.800 Engine speed limitation 1/min [rpm] 9.350 spindle speed 1/min [rpm] 4.300 Displacement Sound pressure level LpA eq per EN 1454 1) dB (A) 99 4) Sound power level Vibration acceleration ah,w per EN 1454 - Tubular handle (idle/rated spindle speed) - Rear handle (idle/rated spindle speed) LWA 110 db(A) 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 Fuel consumption at max. load per ISO 8893 mm (in) 0,5 (.020) l/h (US qt/h) 2,7 (2,9) Specific consumption at max. load per ISO 8893 g/kWh (oz./hph) 500 (13) Fuel tank capacity l (US qt) 1,1 (1,21) 50:1 Mixture ratio fuel/two-stroke oil 5) Cutting blade fer max. 80 m/s (260 ft/sec.) 2) mm (in) 300/20,0/53) (12/0,787/0,2) 350/25,4/53) (14/1/0,2) Arbor diameter mm (in) 20,0 (0,787“) 25,4 (1“) kg ( lb) 10,0 (22) Weight cut-off saw (empty tank, no blade) 1) Figures derived in equal part from idle and max.-speed operation. 2) Circumference speed at max. engine speed. 3) Outside diameter/arbor hole/thickness. 4 ) At the workplace (at user‘s ear). 5 ) With 2-cycle engine oil according to API TC, JASO FC. or ISO L-EGD TD00676GB 33 10,2 (22,5) Denomination of components 6. Denomination of components Identification plate Indicate when ordering spare parts! T00962GB 34 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 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 pulley T00962GB 35 Putting into operation 7. Putting into operation 30 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. For the the following work, use the assembly tools included with delivery: 1.13/19 AF universal wrench 2. Allen key 3. Carburetor adjustment screwdriver 31 1 2 3 Place the cut-off saw on a stable surface and carry out the following assembly steps: T00962GB 36 Putting into operation 7.1 Fitting cutting blades Model 32 Inspect the disc for damage, see 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. ATTENTION: When using a diamond cutting disc be sure to mount it so that it rotates in the proper direction! 33 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 wrench (1). NOTE: Tighten the screw firmly 30 + 2 Nm (22 + 1,5 ft.lbs.), as otherwise the cutting wheel could slip during cutting applications. T00962GB 37 Putting into operation 7.2 Tightening the V-belt/Checking V-belt tension 34 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! 35 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 tightening/inspection, make certain to tighten the fastening nuts (11) 30 + 2 Nm (22 + 1,5 ft.lbs.). T00962GB 38 Putting into operation 7.3 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 cm3 (1 liter) 3 5000 cm (5 liter) 10000 cm3 (10 liter) Us-gal.1,0 Us-gal. 2,5 Us-gal. 5,0 20 cm3 100 cm3 200 cm3 2,5 fl.oz. 6,4 fl.oz. 12,8 fl.oz. The correct mixture ratio: 50:1 50 parts gasoline to 1 part oil. 36 Fuel mixture The cut-off saw is powered by a high-performance two-cycle engine. It runs on a mixture of gasoline 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. T00962GB 39 Putting into operation The 2-cycle engine oil must comply with API TC, JASO FC or ISO LEGD 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. ATTENTION: Open the tank cap carefully, as pressure might have built up inside! It is not wise to add more engine oil than specified to ensure safe operation. This will only result in a higher production of combustion residues which 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. 37 AVOID SKIN AND EYE CONTACT Mineral oil products degrease your skin. If your skin comes in contact with these substances repeatedly and for an extended period of time, it will dry out. Various skin diseases may result. In addition, allergic reactions are known to occur. Eyes can be irritated by contact with oil. If oil comes into your eyes, immediately wash them with clear water. If your eyes are still irritated, see a doctor immediately! T00962GB 40 Putting into operation 7.5 Refuelling Fuel mixture 38 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. 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! T00962GB 41 Putting into operation 7.6 Starting the engine if necessary 39 3 meters (10 feet) 40 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. 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. 41 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.. T00962GB 42 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. 7.7 Cold-starting 42 Move the combination switch (5) upwards (choke position). Grasp handle (hand pressure actuates the grip throttle 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). 43 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 piston is positioned before the top dead centre). Now pull the starter rope with a fast and forceful movement until you hear the first ignition. T00962GB 43 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. 7.8 Warm-starting As described under „Cold starting“, except without moving the combination switch (42/5) to the choke position. 7.9 Stopping the engine 44 Push the combination switch (9) down to position 7.10 Adjusting the carburetor Set the idling speed with a screwdriver (width of blade: 4 mm) (0,16“). The screwdriver shown has a molded-on lug to assist in adjustment. 45 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 running-in process of a new engine may require slight readjustment of the idling speed. T00962GB 44 Putting into operation 46 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). 47 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 T00962GB 45 Maintenance 8. Maintenance 48 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. SERVICE 49 NOTE Because 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 to a WACKER service station for its repair before using the machine again! T00963GB 46 Maintenance 8.1 Changing the V-belt 50 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). Make sure to put them back in the right places during reassembly! 51 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 “Tightening the V-belt / Checking V-belt tension“. T00963GB 47 Maintenance 8.2 Cleaning the protective hood NOTE: See “Fitting cutting blades“ for assembly of blades. 52 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. 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 53 Turn the cover lock (11) to the „Unlocked remover the filter cover (12). “ position and carefully Two sealing rings (54/15) are located between the filter cover (12) and the covering cap (54/14). T00963GB 48 Maintenance 54 Loosen the screws (13) and remove the covering cap (14). Clean the sealing rings (15) with a small brush and check them for damage. 55 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. T00963GB 49 Maintenance 8.4 Prefilter and air cleaner insert 56 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. Cleaning prefilter and air cleaner insert Knock the contaminated prefilter (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 against a clean surface. Additional note: The prefilter may be humidified with oil to increase its filtering performance. Follow manufacturer‘s instructions! ATTENCION: If the air filter becomes damaged, replace immediately! Pieces of cloth or large dirt particles can destroy the engine! T00963GB 50 Maintenance 8.5 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. 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. 57 Turn the cover lock (6) to the “Unlocked remove the filter cover (7). “ position and carefully Flip up spark plug cover (8). Pull plug cap (9) off spark plug. Remove spark plug only by using universal wrench delivered with machine. Electrode gap The electrode gap must be 0.5 mm (0,020“). T00963GB 51 Maintenance 8.6 Checking the ignition spark 58 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!). 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. T00963GB 52 Maintenance 8.7 Replacing the suction head 59 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. 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 60 Loosen four screws (14). Remove the fan housing (15). Unscrew 2 screws (16) and carefully remove air duct (17) from fan housing. Note and follow sequence (A-B-C-D). Remove remainders of old rope (18). T00963GB 53 Maintenance 61 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. Insert knot (22) into the starter handle (23). 62 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 the drum. Repeat procedure three times. The starter handle must stand out from the fan housing. T00963GB 54 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. Assemble air duct in reverse order (see picture 63). Make sure that the guide (25) is located inside the seat (26) at the fan housing. When replaceing fan housing, it may be necessary to pull the starter rope lightly so that the rope pulley catches. 8.9 Replace the return spring 63 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 retum spring (4) from spring holder with screw driver or similar tool. Be extremely careful, as return spring is pretensed and could jump out of spring holder! ATTENCION: Danger of bodily harm! Wear safety glasses and safety gloves under all circumstances! T00963GB 55 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. After greasing insert retum spring (4), press in slightly so that the brackets (5) snap into the seats. Screw in screw (3) and only tighten lightly. Tum rope drum 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 64 NOTE: The cut-off saw is delivered with the cutting arm mounted in the inboard position (1). For cutting up against obstacles, such as curbs or walls, the cutting arm can be mounted to one side (outboard) (2). Use this position only when actually necessary, and afterwards return the cutting attachment to the inboard position. In this position the cut-off saw has better balance, is easier to guide, and is not as fatiguing for the operator. T00963GB 56 Maintenance 8.11 Repositioning the cutting arm 65 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). 66 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. T00963GB 57 Maintenance 67 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). 68 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“. 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! T00963GB 58 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. All such work must be carried out by a WACKER service station. General Before each start Every day Every week Every 3 months T00963GB Entire Power Cut Clean exterior, check for damage. In case of damage, have repaired by a qualified service centre immediately Cutting blade Clutch Inspect regularly for damage and wear. Protection hood Clean, check position 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. Prefilter Clean. (Replace after 20 running hours) Idle speed Check (cutting blade must not turn on idle). Fan housing Clean to ensure proper air cooling. Starter Check for damage. V-belt Check V-belt tension, inspect for damage and wear. Air filter cartridge Clean. (Replace after 100 running hours) Spark plug Check and replace if necessary. Muffler Check tightness of mounting. Suction head Replace. Fuel tank Clean. Bearing Clutch drum Clean and regrease. 59 Maintenance Storage T00963GB 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. 60 Maintenance 8.13 Troubleshooting T00963GB Malfunction System Observation Cause Cutting blade does not start turning Clutch Engine runs Damage to clutch Cutting blade turns while engine idles Carburetor, Clutch Cutting blade turns Incorrect idle speed, clutch stuck Engine does not start or only with difficulty Ignition system Ignition spark Malfunction in fuel supply system, compression system, mechanical malfunction. No ignition spark Switch on STOP, fault or short-circuit in the wiring, plug cap or spark plug defective. Fuel supply Fuel tank is filled Choke in wrong position, carburetor defective,suction head dirty, fuel line bent or interrupted. Compression 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. Engine does not start or only with difficulty Fuel supply Fuel tank is filled Wrong idling adjustment, suction head or carburetor dirty. Tank venting defective, fuel line interrupted, cable defective, Stop switch defective. Starting valve dirty. Low performance Serveral systems may be involved simultaneously Engine is idling Air filter dirty, wrong carburetor adjustment, muffler clogged, exhaust channel in cylinder clogged. 61 FBTS 9. FBTS 9.1 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. 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 depth of the blade. One notch is equivalent to 10 mm (0,4“) cutting depth. T00964GB 62 FBTS 9.2 T00964GB 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 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 rolling away. 9.2.6 Push the throttle lever to the idle position (forwards) immediately after ending the cutting process. 63 Labels 10. Labels SK00658GB 1 Fuel to oil ratio 2 Wacker Logo 3 Type 4 Cover safety 5 Protective hoad safety 64 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 ... / 0008341 ... 0008987 ... / 0008988 ... 0008339 ... / 0007975 ... / 0008912 ... 0008989 ... / 0008990 ... 4. absolute installed power: 3,2 kW 4,2 kW has been evaluated in conformity with Directive 2000/14/EC: Conformity assessment procedure Annex V Measured sound power level Guaranteed sound power level BTS 930/935L3 BTS 1030/1035L3 109 dB(A) 110 dB(A) 111 dB(A) File certificate carefully and has been manufactured in accordance with the following directives: * 2000/14/EG * 89/336/EG * 98/37/EG Dr. Sick Board of Directors C0003106GB DIN EN ISO 9001 CERTIFICATE