BTB ETS1200 E-Tool User Manual

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Removal System for

Adhesive Bonded

Glass and Panels

ETS1200

User Manual

PATENTED DESIGN

BTB has Registered and Pending Patents and/or Designs Extending Worldwide applying to their Power Tools, Control System, and Cutting Blades.

The Battery Powered

Auto Glass Cut-Out Tool

Designed and Built specically

The proven BTB System is available

with either the BTB E-Tool for total

portability or with the WK10HD Air

Tool for heavy duty applications and

workshop-based glass removals.

for Mobile Installations

The uses the same

famous BTB Blade & Cutting Depth Control System and has the same great features as the

BTB WK10HD Air Tool and more.

Same Kits with a choice of power tool.

Air Tool

Contents

ADHESIVE

PINCHWELD

GLASS

PCK BLADE

ADHESIVE

PINCHWELD

GLASS

REVERSE PCK BLADE

ADHESIVE

PINCHWELD

GLASS

REVERSE PCK BLADE

ADHESIVE

PINCHWELD

GLASS

ADHESIVE

GLASS

USE BLADE FROM OUTSIDE VEHICLE

PCK BLADE

‘A’

PILLAR

ADHESIVE

PINCHWELD

GLASS

REVERSE PCK BLADE

TRIM

1. Introduction: Power Tool and Safety _______________ Page 3

1.0.1 Tool and Kit Part Numbers for Re-O rdering

1.0.2 Warranty and Serial Number Location

1.1 Reciprocating Power Tool SafetyInstructions __________________ Page 3

1.1.1 Operator Safety

1.1.2 Power Tool Operation Safety

1.1.3 Vehicle Safety

1.2 Vibration Emission Levels ______________________________ Page 4

1.3 EC Declaration Of Conformity ____________________________ Page 4

1.4 Technical Specications _______________________________ Page 4

1.5 Power Tool Operation ________________________________ Page 4

1.5.1 Tool Duty Cycle Times & Overload Shut Down

1.5.2 Power On/O Slide Trigger

1.5.3 Speed Control Switch

1.5.4 LED Light Warnings

1.6 Power Tool Maintenance ______________________________ Page 5

1.6.1 Oiling The Felt Seal

1.6.2 Cleaning The Tool

1.7 Batteries & Alternate 12V Power Supply _____________________ Page 5

1.7.1 Battery Use

1.7.2 Battery Charging & Life Span

1.7.2.1 BATTERY CHARGER LED INDICATOR LIGHTS

1.7.3 Battery Storage

1.7.4 Battery Disposal

1.7.5 Alternate 12Volt Power Supply Options

2. Cut-Out Guidelines & Examples ___________________ Page 6

2.1 Blade Types, Blade Usage, Blade Depth Control _________________ Page 6

2.1.1 SIX BASIC BLADE TYPES

2.1.1.1 STANDARD NON-SERRATED AND SERRATED BLADES

2.1.2 Fitting and Changing Blades in the Power Tool

2.1.3 Sharpening Blades

2.1.4 Replace Worn Blades

2.1.5 Cutting Lubricant is Important

2.1.6 Blade Vibration When Cutting Internally

2.1.7 Protect Glass and Painted Panel Surfaces

2.1.8 Rest the Nylon Controller Cap Against the Glass

2.1.9 Adjustable Cutting Depth Controller Arms

2.1.9.1 SELECTING CONTROLLER ARMS

2.1.9.2 SETTING BLADE DEPTH CONTROL

2.1.9.3 USING CONTROLLER ARMS ON TOP OF CUTTING BLADES

2.1.9.4 USING WK11CW CONTROLLER ARM UNDER 'R' BLADES

2.1.9.5 SPACING CONTROLLER ARMS AWAY FROM GLASS

2.2 Cut-Out Planning & Instructions _________________ Page 7

2.2.1 Cutting From Inside Vehicle

2.2.1.1 PREPARE TO START CUTTING FROM INSIDE

2.2.1.2 CORRECT CUTTING USING STANDARD INTERNAL CUTTING BLADES

2.2.1.3 INCORRECT & INEFFICIENT CUTTING

2.2.1.4 REMOVING WINDSHIELDS WHILE STANDING IN DOORWAY

2.2.2 USING LONG BLADES FOR HARD TO REACH AREAS & SMALL GLASSES

2.2.2.1 EXTRA HARD AND / OR WIDE ADHESIVE

2.2.2.2 REMOVING GLASS WHERE GLASS AND ADHESIVE IS COMPRESSED CLOSE TO THE PINCHWELD

2.2.3 Removing Glass Fitted With Applied Mouldings

2.2.4 Flexible Blades for Curved Glass

2.2.5 Undamaged and Risky Glass Removal

2.2.6 Removal of Cracked or Badly Damaged Laminated Glass

2.2.7 Encapsulated Glass Removal using Reverse 'R' And Reverse 'VR' Standard Serrated Blades

2.2.7.1 REMOVAL OF ENCAPSULATED GLASS FOR RE-INSTALLATION

2.2.7.2 REMOVAL OPTIONS FOR UNUSABLE / DAMAGED ENCAPSULATED GLASS

2.2.8 Exposed or Bare Edged Glass

2.2.9 Cutting from Outside the Vehicle with Standard Flat Blades Or 'ZR-S' Blades

2.2.10 Cutting from Outside Vehicle with a Powered Cold Knife (PCK) Blade

2.2.10.1 GUIDELINES FOR USING WK27 & WK28 POWERED COLD KNIFE BLADES

2.2.10.2 CORRECT BLADE & TOOL ALIGNMENT FOR EFFICIENT CUTTING USING PCK

BLADES

2.2.11 Pinchweld Trimming With No Damage to Paintwork

2.2.12 Backll Adhesive Removal (Bus & Train Glasses)

2.2.12.1 REMOVING BACKFILL USING A WK5-S BLADE

2.2.12.2 REMOVING BACKFILL USING A WK17 CHANNEL BACKFILL BLADE

2.3 Bonded Panel & Glass Roof Removal ______________________ Page 12

2.3.1 Bonded Panel & Roof Module Frame Removal

2.3.2 Panoramic Glass Roof Removal (See also 2.3.1)

2.4 Removing Side Mouldings & Emblems _____________________ Page 13

2.5 Using the Tool as a Power Hacksaw _______________________ Page 13

3. Troubleshooting _______________________________ Page 13

4. Hints, Tips and Operating Techniques ____________ Page 14

4.1 Standard Blades (Including Serrated Blades) _______________________________ Page 14

4.2 Powered Cold Knife Blades (WK27 and WK28 Blade range) ____________________________ Page 14

5. Tool Repair & Part Replacement _________________ Page 14

6. Spare Parts ___________________________________ Page 14

7. Blade Chart ___________________________________ Page 15

ALSO REFER PAGES 6 to 11 ALSO REFER PAGES 6 to 11

the Vehicle

Encapsulated Glass

Short Blade

WK4ZR-S

WK4ZVR-S

Longer

Blade*

WK4R-S

WK24ZR-S

WK24ZVR-S

Can Cut from

Exposed / Bare Edge Glass

YELLOW

If adhesive is

accessible Powered Cold Knife blades can cut out the entire top

and side and bottom

of a windshield or side glass in the same way as a manual cold

knife blade.

then standard blades can also be used from

Diagram P (Page 9) and

CUT-OUT PLAN & BLADE SELECTION REFERENCE

OUTSIDE

With Standard BladesWith PCK Blades With PCK Blades

YELLOW OR ORANGE

If glass is fully or

partially exposed

the outside. Refer

Diagram X (Page 10).

the Vehicle

Encapsulated Glass

ORANGE

Reverse Powered

Cold Knife blades are used where this reverse grind blade

can enter under

the encapsulated

moulding and will

cut close against the

pinchweld surface.

Must Cut from

INSIDE

NO Blade Access from Outside Glass

With Standard Blades With Standard Reverse Blades

FLAT Glass

Short Blade

WK4Z

WK4Z-S

Longer

Blade*

WK3 / 3-S

-* Optional longer blades:-

WK4 / 4-S

CURVED Glass FLAT Glass CURVED Glass

Short

Blade

WK24Z

WK24Z-S

Longer

Blade*

WK4 / 4-S

WK24/24-S

WK2 / 2-S, WK1 / 1-S, WK1X or WK1ZX

Do not use a long blade if a short blade does the job.

2 © BTB Auto Glass & Body Shop Tools

ALWAYS use controller arms to a) regulate blade cutting depth, b) provide precision and

stability to the blade cutting action, or c) provide valuable condence to the operator.

Diagram A

Short Blade

Longer

Blade*

WK4R-S

WK24R-S

WARNING! Before using, servicing, changing blades on or working near this tool/kit, read all safety instructions and warnings, including those given in the training video. Failure to follow the warnings and instructions may result in injury and/or property damage. Care and good judgement are the best protection against injury.

Store this user manual for future reference.

1. Introduction: Power Tool and

Safety

BTB’s patented windshield and auto glass removal tool successfully removes all types of adhesive set automotive glass and components including glasses with bonded mouldings, encapsulated mouldings and/or where the adhesive is located away from the edge of the glass, or hidden far below the dashboard area. The blade reciprocates against the surface of the glass OR the pinchweld / car body, to quickly and eciently cut the adhesive. Force is eliminated and expensive undamaged glass and mouldings may be reused. A certain level of skill and prociency quickly develops from applying the tool to a range of cut-out types.

1.0.1 Tool and Kit Part Numbers for Re-Ordering

The E-Tool power tool may have been supplied on its own or as part of a kit. Part numbers for the tool and most common kits are:

• ETS1200 - E-Tool (Power Tool Only)

• ETK1205 - E-Tool+5Ah Battery Pack+Charger

• ETS12B5 - E-Tool 5Ah Battery Pack

• ETK12STR - Starter 4 Blade Kit (includes ETK1205)

• ETK12CLS - Classic 7 Blade Kit (includes ETK1205)

• ETK12TEC - Technician 11 Blade Kit (includes ETK1205)

When ordering product your country/region should be specied to ensure the correct power cord for the charger is supplied.

For user instructions for the WK10HD BTB Air Tool please refer to its separate user manual.

This tool incorporates a diagnostic feature where BTB and BTB's authorised repair agents will both be able to determine abuse or overloading of the tool.

Please review section 3 Troubleshooting (page 13) prior to returning for repair.

Section 1.6 Power Tool Maintenance (page 5) provides some guidelines which will help extend the life of the tool.

When returning a tool for service or repair, send the tool, freight prepaid, to your BTB supplier or authorised BTB repair agent. Please include your contact details and the reason for returning the tool, noting any symptoms.

1.1 Reciprocating Power Tool SafetyInstructions

Do not use this product in any way other than for normal use as stated.

1.1.1 Operator Safety

• Always wear impact resistant eye protection such as safety

glasses or goggles when operating the tool.

• For hand and nger protection, use of protective gloves is

recommended.

• Wear sturdy nonslip footwear.

• Maintain a balanced body position and secure footing when

operating the tool.

• Take care when handling blades as cutting edges are sharp.

• Always sharpen blades in a direction away from your hands.

• Ensure the blade retaining screw is tight when securing blades in

the power tool.

• Do not bend blades or blade cutting tips in an incorrect manner

or use them for purposes other than which they are designed, as blade breakage could occur.

• Do not use cracked or distorted blades.

• When cutting adhesives, always use cutting lubrication to

avoid heat build up and possible toxic smoke produced from overheated adhesive.

1.0.2 Warranty and Serial Number Location

The serial number for your power tool can be found:

a. on a temporary tag attached to the power cord, and

b. permanently marked into the front of the guide bush

housing underneath the controller cap. Remove the two screws (SPB32) and controller cap (SPB34K) to access. See Diagram ZH.

BTB provides a warranty from your date of purchase on the following E-Tool kit components. Warranty is subject to valid proof of purchase and the following:

E-Tool Mechanism, Electronics & Other Accessories ............1 year

Battery ..................................................3 months

Blades ..........................................................Nil

Any part found to be defective in material or workmanship within its listed warranty period from date of purchase will be repaired or replaced at BTB’s discretion. BTB, its distributors and/or its authorised repair agents reserve the right to refuse any claim where the purchase date cannot be veried.

This warranty does NOT cover fault and/or damage caused by foreign objects or contamination entering the power tool, neglect, lack of/incorrect lubrication, evidence of abuse, overloading and/or overheating, any modication, or every-day wear and tear.

1.1.2 Power Tool Operation Safety

• Always turn o or disconnect the tool from the power supply

when changing blades or when the tool is not in use.

• Do not start the power tool until the tool and blade are in a safe

correct operating position.

• Do not let any cutting lubricant or water enter the tool or motor.

If this occurs, avoid using the tool until any moisture has had sucient time to dry.

• Only use recommended blades or accessories in the power tool.

• The tool, blades and accessories must not be modied.

• Always check for damaged or loose power cord or ttings.

1.1.3 Vehicle Safety

• Remove all loose dirt, grit or debris from glass edges before

proceeding with cut-out.

• Cover vehicle roof, hood or bonnet, interior seats and carpets

with protective covers prior to cutting.

• If necessary, remove internal and external trims or mouldings, or

apply protective/masking tape to protect paintwork and trims.

• Prior to cut-out, locate and identify ttings on the glass such as

electrical connections, heater elements and rain sensors etc.

• E-Tool can be powered by an applicable special high amp draw

12 volt socket if it has been tted to a vehicle. Do not plug the E-Tool into a vehicle’s standard 12 volt cigarette lighter socket.

3© BTB Auto Glass & Body Shop Tools

1.2 Vibration Emission Levels

OFF

LOW

HIGH

SPEED CONTROL SWITCH

RED LED

SLIDE TRIGGER

GREEN LED

VENTILATION WINDOWS

1.5 Power Tool Operation

The vibration emission level of the tool has been measured in accordance with a standardised test given in EN 60745 and may be used to compare one tool with another. It may be used for a preliminary assessment of exposure.

The declared vibration emission level represents the main applications of the tool. However if the tool is used for dierent applications, with dierent accessories or is poorly maintained, the vibration emission may dier. This may signicantly increase the exposure level over the total working period.

Vibration Total Value: .....................................8.03 m/s

Daily Exposure Action (EAV) Duration: ....................0hr 46min

Daily Exposure Limit (ELV) Duration: ......................3hr 31min

Based on the results the E-tool can be used to cut out 9 windscreens which have an average actual cutting time of 5 minutes each (9 x 5min = 45min) to stay within the 46min EAV limit without requiring the implementation of management programs to reduce exposure and risk.

An estimation of the level of exposure to vibration should also take into account the times when the tool is switched o or when it is free running but not actually doing the job. This may signicantly reduce the exposure level over the total working period.

Additional safety measures to protect the operator from the eects of vibration include: maintaining the tool and the accessories, keeping hands warm, organisation of work patterns, adhering to a duty cycle times for heavy duty work. Refer to section 1.5.1 Tool Duty Cycle Times.

Testing carried out at BTB Tools by Computerised Bearing Analysis (Aust) Pty Ltd identied the main operational factors that contribute to high vibration levels during use of the E-Tool:

• Excessively pushing or forcing the tool and blade rather than letting the tool do the cutting.

• Forcing the cutting process until the blade jams in the adhesive.

• Not applying cutting lubrication regularly as instructed or

improperly applying it prior to cutting.

• Using the wrong blade or not aligning the blade tip correctly.

• Contact with metal body (e.g. pinchweld) or mouldings and

ttings of the car.

• Using blades that have not been kept sharp.

• Using blades that are not specied to t the BTB system.

1.5.1 Tool Duty Cycle Times & Overload Shut Down

BTB’s E-Tool is designed for technicians carrying out in-shop and mobile domestic vehicle glass removals, with short/quick actual cutting periods e.g. 2- 8 minutes (average 5 minutes) per job.

When used eciently and appropriately, BTB’s E-Tool is also excellent for incidental bus / train glass cut-outs and bonded panel removals. These applications often involve wide and hard adhesive and large, thick, rigid glasses requiring heavy duty continuous

cutting, which may result in excessive heat build-up. If this happens, BTB recommend 10-15 minutes of continuous cutting then to stop the tool to allow an adequate cooling down period before continuing. The tool incorporates an overload protection feature and will shut down repeatedly if overloaded. The tool will re-start by releasing and re-engaging the On/O slide trigger.

Faster cut-out and longer life-span of the tool results when the E-Tool is operated eciently and used as instructed, including the use of cutting lubrication. Inecient use with lack of lubrication and overloading of the E-Tool will result in a slower cut-out and a shorter tool life span of the tool.

Repeated overload may void warranty of the tool if evidenced by the diagnostic feature of the E-Tool. Refer to section 1.0.2 Warranty and Serial Number Location (Page 3).

1.5.2 Power On/O Slide Trigger

The slide action trigger caters for multiple hand locations. Finger pressure locks at the front, centre and rear of the trigger hold the tool in the ON position. Auto OFF with trigger release.

1.5.3 Speed Control Switch

O = Switch at 0 position.

Low Speed = Switch at I position (Green LED blinks).

High Speed = Switch at II position (Green LED is continuously lit).

BTB Tools recommends against all of above.

Diagram B

1.3 EC Declaration Of Conformity

We declare under our sole responsibility that this product is in conformity with the following standards or standardized documents: EN 60745, EN 55014-1, EN 55014-2, in accordance with regulations and directives 2009/127/EC, 2004/108/EC and 2002/44/EC

1.5.4 LED Light Warnings

If Red LED blinks while trigger in ON position = Overload Warning (Tool Stops to indicate abusive load - Auto Reset on trigger release).

If Red LED is continuously lit while trigger in ON position = Low Battery Warning, re-charge battery.

1.4 Technical Specications

Free Speed .....................................6400 strokes/min

Reciprocating Stroke Length ...............................4 mm

Noise at 1.0 metre ........................................ 80 dBA

Motor Power Output ....................................112 W

Voltage Input ............................................12 V DC

Tool Weight ..............................................1.3 kg

Overall Length Excluding Power Cord ....................280 mm

Vibration emission value (vector sum in three axes) ahv ...8.03 m/s

4 © BTB Auto Glass & Body Shop Tools

1.6 Power Tool Maintenance

OILING

HOLE

Use only BTB accessories and spare parts. If components need to be replaced which have not been described, please contact your BTB supplier.

1.6.1 Oiling The Felt Seal

It is important to regularly oil the felt seal to protect the chuck drive shaft from water/dust ingress. Oil should only be applied to the small countersunk hole located in the controller cap behind the securing screws. Using the oil bottle supplied, apply 3 to 4 drops of oil, one drop at a time, while the tool is running on low speed. If excess oil appears from chuck area, cut back on the number of drops applied. Mobil DTE 10 Excel 68 is supplied / recommended. If the recommended oil is not available, use multi-purpose ne grade power tool oil.

Diagram C

Use the charger indoors only. If the charger is exposed to rain or moisture, refer service to an authorised service & repair agent.

The charger cord must be plugged into a properly installed outlet and grounded in accordance with all local and national codes and ordinances.

The charger housing may become warm during the charging cycle.

Do not leave charger plugged in when not connected to a battery.

Make sure any cords are located so that they will not be stepped on, tripped over, or otherwise subjected to damage or stress. Do not operate the charger with a damaged cord or plug – replace the complete unit immediately. To reduce risk of damage to the electric plug, disconnect charger by pulling by plug rather than cord.

Do not operate charger if it has received a sharp blow, has been dropped, or is damaged in any way. Do not disassemble the charger. Refer service to an authorised service & repair agent.

Recharge batteries in a well ventilated area to prevent potential build-up of explosive gases. Allow adequate space and air circulation around the charger to reduce internal heat buildup.

Always keep children away from charging equipment when in use. Do not allow them to handle or play with chargers when not in use.

1.6.2 Cleaning The Tool

The ventilation windows of the tool and the sliding trigger should be kept clean and clear at all times. Refer to Diagram B.

1.7 Batteries & Alternate 12V Power Supply

1.7.1 Battery Use

Make sure battery terminals are connected correctly. The E-Tool features reverse polarity protection, so the tool will not work if the battery terminals are connected incorrectly.

A fully charged 5.0Ah E-tool battery should have enough charge to cut out 9 windscreens when used under normal cutting conditions and assuming an average actual cutting time of 5 minutes each.

Battery packs which have not been used for some time should be recharged before use. The battery will give best performance and last longest if maintained at full charge. BTB recommends the

battery is placed on charge after each use or at least once daily.

Temperatures in excess of 50°C (122°F) reduce the performance of the battery pack. Extended exposure to heat or direct sunlight may cause the battery to overheat.

The electrical contacts of chargers and battery packs must be kept clean. The leads inside the battery bag which connect the spade terminals of the battery to the merit plug must be securely attached to maintain optimum power/performance.

1.7.2 Battery Charging & Life Span

1.7.2.1 BATTERY CHARGER LED INDICATOR LIGHTS

The BTB supplied battery charger LEDs glow:

Green when connected to AC power without a battery inserted

Red when a battery is being charged

Green when a battery is nearly fully charged and during trickle/oat

charge.

1.7.3 Battery Storage

Batteries should be stored in a safe dry place away from oil and re and be kept dry at all times. A temperature of around 20°C is desirable. It is important that the battery is charged at least

every six months if stored, otherwise permanent loss of capacity might occur.

Do not store the battery pack together with metal objects to avoid risk of short circuit.

Never break open battery packs and chargers.

Battery acid may leak from damaged batteries under extreme load or extreme temperatures. In case of contact with battery acid, wash it o immediately with soap and water. In case of eye contact rinse thoroughly for at least 10 minutes and immediately seek medical attention.

1.7.4 Battery Disposal

Never throw a battery into a re.

Batteries should be disposed of in an environmentally friendly manner.

Batteries must be recharged between uses for optimal battery life and must remain in the battery bag during charging. Do not charge the E-Tool batteries with a charger other than that supplied or recommended by BTB Tools or warranty will be void.

Charging time depends on the battery charge level before charging. Maximum charge time of the supplied E-Tool battery using the E-Tool Smart Charger (included in E-Tool kits) is 90minutes, however, overnight charging of your E-Tool battery will further increase usage time. Avoid charging any longer than this period.

The charger will automatically switch into a single stage, oat (trickle) charge mode when the battery is charged but is not designed to operate as a standalone power supply.

All batteries wear out over time and periodically need to be replaced. When the battery's operating time becomes noticeably less it should be replaced. A three (3) month manufacturer's warranty is provided on batteries supplied by BTB Tools.

1.7.5 Alternate 12Volt Power Supply Options

The E-Tool can be powered by any reliable 12 Volt source tted with wiring and sockets compatible with the E-Tool merit plug and able to supply 10 - 15 Amps and occasional 20 Amp spike draw. These include:

• Mobile vehicle 12 Volt battery power utilising an appropriate extension power cord.

• Portable 12 Volt jump-start battery pack.

• Larger 12 Volt battery connected via appropriate power leads.

• AC to 12 Volt DC power transformer for use where AC power is

readily available.

5© BTB Auto Glass & Body Shop Tools

2. Cut-Out Guidelines & Examples

serrated

GREEN 'V'

ORANGE 'R'

YELLOW

BLUE 'VR'

straight bent Z style spade

Yellow or Green blades have the at side of their cutting tip down. Green 'V' blades are a safety edge version of the yellow blades Orange or Blue (reverse) blades have the at side of their cutting

tip up (bent opposite to Yellow and Green blades). Blue 'V' blades are a safety edge version of the orange blades.

ORANGE 'R'

YELLOW

Powered Cold Knife (PCK) Blades Winged Pinchweld

Scraper Blades

Yellow blades have the at side of their

cutting tip up. Orange blades have the at side of their cutting tip down.

Radius grind of cutting tip won't scratch vehicle paintwork.

non-serrated

Standard Blades

WK11BW5 CONTROLLER ARM

WHEEL STOPS AT PILLAR TRIM

INTERIOR ROOF LINER

OR PILLAR TRIM

CAR

BODY

Z BLADE

GLASS

NYLON CONTROLLER CAP

RESTS AGAINST GLASS SURFACE

ADHESIVE

2.1 Blade Types, Blade Usage, Blade Depth Control

Details of BTB's full product range can be found in our dedicated Removal System catalogue supplied with the power tool, and available for viewing or downloading from BTBTOOLS.COM. A training video can also be viewed from this website.

2.1.1 SIX BASIC BLADE TYPES

• Standard Straight Blades

• Standard Bent Blades

• Standard "Z" Blades

• Standard Spade "Z" Blades

• Powered Cold Knife Blades

• Winged Scraper Blades

Variations of these include:

• Length up to 375 mm

• Flexibility of blade tip

• Serrated or Non-Serrated

• Cutting Tip Length of PCK blades

• Wing Width of Scraper Blades

• Cutting Tip Prole (designated by colour, see below)

Refer to Diagram A

on page 2 and Section

2.2 on page 7 to plan your cut out.

Refer to Hints, Tips and

Operating Techniques

on page 14 for further blade use guidelines.

A full blade list can be

found on page 15.

via the hole in the controller cap) two full rotations counter clockwise. Insert the blade as far as it will go into the chuck and rmly re-tighten retaining screw in clockwise motion. Check that the blade is securely held before reconnecting or turning on power.

NOTE: All blades will also t in the WK7 and WK7L manual handles.

2.1.3 Sharpening Blades

The best cutting results are obtained with sharp blades. The procedure for sharpening the blades is as follows:

1. Sharpen blades from radiused (rounded) side only.

2. Keep at side of blade smooth to allow sliding motion on the glass surface.

WARNING: COARSE GRINDING OR BLUNT BLADES WILL SERIOUSLY REDUCE PERFORMANCE, EFFICIENCY AND SAFETY.

2.1.4 Replace Worn Blades

If shape / length of blade tip reduces from repeated sharpening, or is varied from its original shape, replace blade to regain eciency.

2.1.5 Cutting Lubricant is Important

Using Cutting lubrication is important for blade movement. Always spray both the inside and the outside of the glass where possible. Use water or a cutting lubricant / additive mixed with water that has been approved by your adhesive manufacturer.

2.1.6 Blade Vibration When Cutting Internally

If a blade vibrates or aps against the glass, the operator is doing something wrong. Refer to the following points 1, 2 and 3 below and also Diagrams J, K and Diagram L.

1. Check blade tip is at against the glass or panel.

2. Ensure blade and tool are held rm, the angle is correct, and the controller cap is against the glass.

3. When cutting below dashboard with long blade, keep tool and blade in straight line. See Diagram L and Diagram M.

2.1.7 Protect Glass and Painted Panel Surfaces

As an extra precaution to avoid scratching the glass with the back of the cutting blade, you can apply a small Velcro® pad (supplied in kits) to the oending section of the blade. Ensure the blade is dry. The WK11PP paint protector controller arm can be used in

2.1.1.1 STANDARD NON-SERRATED AND SERRATED BLADES

Non-Serrated blades can be used in all glass and panel applications. Serrated blades are optional and can provide a faster more

aggressive cutting action.

Diagram D

conjunction with external Powered Cold Knife blades.

2.1.8 Rest the Nylon Controller Cap Against the Glass

The nylon controller cap will not scratch glass or panel and is to be held against the glass surface for internal cutting. This also guarantees ecient cutting and operator control because the blade and cutting tip is held at the correct angle and hugging the glass surface. It is also designed to attach blade cutting depth controller arms. See also 2.1.9 Adjustable Cutting Depth Controller Arms (page 7).

2.1.2 Fitting and Changing Blades in the Power Tool

To t blades, always turn power switch to the OFF (right) position or disconnect the power cord. Using the 4.0mm WKKEY Allen key provided, unscrew the SPB33 cone point retaining screw (located

6 © BTB Auto Glass & Body Shop Tools

Diagram E

2.1.9 Adjustable Cutting Depth Controller Arms

CONTROLLER ARM

NYLON CONTROLLER CAP RESTS

AGAINST GLASS AND SECURES

DEPTH CONTROL ARMS

CUTTING

DEPTH

(A)

(B)

(C)

WK11BW5

CONTROLLER ARM

PINCHWELD

ADHESIVE

PILLAR TRIM

or HEADLINER

CAR

BODY

BLADE

GLASS

PINCHWELD

ADHESIVE

ENCAPSULATED

MOULDING

FLAT SIDE OF ORANGE

OR BLUE REVERSE BLADE

AGAINST PINCHWELD

CONTROLLER

CAP

CONTROL ARM

UNDER BLADE

PROTECT

PILLAR TRIM

OR HEADLINER

SPACE CAN BE FILLED BY

ADHERING VELCRO® TABS

TO WHEEL.

A range of controller arms are provided with each toolkit to provide precise cutting depth control, avoiding damage to blade, pinchweld, mouldings and glass. These are to be used against the rounded side of the cutting blade tip. They can be quickly attached into the controller cap jaw and adjusted to required depth.

Diagram H

2.2 Cut-Out Planning & Instructions

Diagram F

2.1.9.1 SELECTING CONTROLLER ARMS

Controller arms with a Thick Nylon roller wheel are for use with the wheel rolling against the head liner or trim. See Diagram E.

Controller arms with a Thin Steel roller wheel are for use with the wheel rolling against adhesive. See Diagrams H, M, U and Diagram V.

For the full range of controller arms refer to the table in section 7 .

2.1.9.2 SETTING BLADE DEPTH CONTROL

Refer following instructions together with the example in Diagram G.

A. Place blade tip against adhesive

B. Calculate adhesive thickness

C. Adjust controller arm wheel a distance away from stop point

C and equal to adhesive thickness B.

Refer Diagrams U, V, E , G, H, ZB and Diagram ZC.

IMPORTANT! CONSIDER ALL OPTIONS AND PLAN YOUR CUT-OUT FIRST.

When planning a cut-out many factors need to be considered. For example:

The same glass may require dierent cut-out techniques.

A. Damaged glass has less risk and may be removed

more aggressively and quickly. Refer to Diagram W on page10.

B. Undamaged glass (to be reinstalled) has high risk and

requires a patient, stress free and well-planned cut-out, which may require a combination of cutting from both inside and outside of the vehicle.

Take advantage of BTB’s versatile and precise system which allows you to cut the adhesive:

a. from outside the vehicle

b. from inside the vehicle

c. against surface of glass

d. against surface of pinchweld/panel

e. combining the cutting from inside and outside as a

solution for dicult removals.

2.1.9.3 USING CONTROLLER ARMS ON TOP OF CUTTING BLADES

Mostly used on top of blades while the at side of the blade reciprocates against glass surface. Refer Diagram F and Diagram G.

2.1.9.4 USING WK11CW CONTROLLER ARM UNDER 'R' BLADES

To steer the ORANGE and BLUE "Reverse" blades safely away from and encapsulated glass, the WK11CW controller arm is tted under an "R-S" or "VR-S" blade to cut against the pinchweld and NOT against the glass. The Control arm provides critical support to the reciprocating blade, besides blade depth control. Refer to Diagrams H, U and Diagram V.

2.1.9.5 SPACING CONTROLLER ARMS AWAY FROM GLASS

Fit Velcro® pads to Controller Arm Wheel to further space Control Arm away from glass. Velcro® pads can also stop unnecessary noise. Refer Diagrams H, M and Diagram V.

Diagram G

Use this user manual as a reference document. Specically the following sections:

• Cut-Out Plan & Blade Selection Reference (DiagramA, page 2)

• Blade Types shown (Diagram D, page 6)

• Hints, Tips and Operating Techniques (page 14)

• Blade Chart (page 15)

• The many practical examples in this user manual.

Now select a cutting blade type and colour which allows the blade cutting tip to cut the adhesive:

A. with the at side facing and against the glass surface

(DiagramG and Diagram N)

B. with the at side facing and against the pinchweld or

panel surface (Diagrams H, U and V)

Select depth control arm. See 2.1.9 Adjustable Cutting Depth Controller Arms section.

7© BTB Auto Glass & Body Shop Tools

2.2.1 Cutting From Inside Vehicle

GLASS

PINCHWELD

LONG STRAIGHT

BLADE

CONTROLLER CAP RESTS

AGAINST GLASS

PINCHWELD

BLADE FORCED

TO UNNATURAL

BENT POSITION

GLASS

HAND BETWEEN

POWER TOOL

AND GLASS

LONG STRAIGHT

BLADE

LONG STRAIGHT

BLADE

GLASS

LONG STRAIGHT

BLADE

CONTROLLER

CAP

FRONT

WINDSHIELD

CAR BODY

HOOD /

BONNET

DASHBOARD

ADHESIVE BELOW

DASHBOARD

CONTROL ARM WHEEL STOPS

AT ADHESIVE

ADHERING A VELCRO® TAB

CAN REDUCE BLADE NOISE

INTERNAL TRIM

ADHESIVE

DO NOT PUSH BLADE INTO ADHESIVE BEFORE STARTING THE TOOL.

MOULDING

“A” PILLAR

Cutting along

an A-Pillar

(viewed from

outside vehicle).

2.2.1.1 PREPARE TO START CUTTING FROM INSIDE

a. Fit cutting blade and depth controller arm if needed

b. Spray cutting lubrication to the immediate cutting area

c. Position the tool and blade against the glass. Refer to

Diagram N. Also note controller cap against glass as shown in diagrams on page 7, 8, and 9

d. Don’t push blade into adhesive before starting the tool.

Refer Diagram N

e. Start the tool and proceed to cut the adhesive

f. For narrow bands and/or softer adhesive, operate the tool

and blade at 45° to 90° and encourage fast and continuous cutting using the tip and side of the blade. Refer Diagram Q.

2.2.1.2 CORRECT CUTTING USING STANDARD INTERNAL CUTTING BLADES

The correct method of operating the power tool using a long straight blade is shown in Diagram J and Diagram M. The controller cap and blade are at against the glass and the operator’s hand is placed under the tool to allow the back of the power tool to also operate as close to the glass as possible. Note, the operator’s thumb is on the tool’s trigger. Refer to 2.2.1.4 Cutting Below Dashboard while Standing in Doorway.

Diagram J

2.2.1.3 INCORRECT & INEFFICIENT CUTTING

Diagram K shows the incorrect method of operating the power tool with a long straight blade being forced into an unnatural bent position and the hand is placed incorrectly between the power tool and the glass surface. This will cause blade vibration and 'apping', plus inecient cutting of the adhesive, especially when cutting below dashboards.

Diagram L

Diagram M

Diagram K

2.2.1.4 REMOVING WINDSHIELDS WHILE STANDING IN

Standing in the doorway while cutting below a dashboard or along top and sides of windshield provides a technician comfort and allows viewing the cut-out through the glass from outside vehicle. When cutting below dashboard, hold the tool in one hand with an

DOORWAY

outstretched arm and thumb on the trigger, cut the central region back to the A-pillar/lower corner, using two hands when able. When changing to other side of vehicle, if you want to maintain your thumb on the trigger, remove the blade, rotate it 180° and re-insert into tool. See Diagrams J, K, L, M and Diagram N.

8 © BTB Auto Glass & Body Shop Tools

2.2.2 USING LONG BLADES FOR HARD TO REACH AREAS &

SMALL GLASSES

Long straight blades are used to reach and cut hidden adhesives. Many small glasses (including encapsulated) can be safely removed using methods shown in Diagram P and Diagram X.

Use the at side of a standard long straight blade to cut against the glass, OR for encapsulated glasses turn blade over so that the at side is cutting against the pinchweld. The blade cuts (1)st section of adhesive then (2)nd section of adhesive. Refer to Diagram P.

Diagram N

WK1

LONG BLADES REACH FROM

1ST

SIDE OF GLASS

THROUGH PRE-CUT

ADHESIVE TO

2ND SIDE DIFFICULT TO

REACH ADHESIVE

CUT AGAINST GLASS OR

FOR ENCAPSULATED GLASSES CUT AGAINST PINCHWELD

QUARTER

GLASS

GLASS GLASS

INTERNAL

TRIM

PINCHWELD

PRE-CUT

ADHESIVE

DIFFICULT TO

REACH ADHESIVE

Diagram P

JABBING BLADE QUICKLY IN AND OUT OF ADHESIVE

WHILE KEEPING TOOL & BLADE MOVING LEFT TO RIGHT

45° 90°

HARD

OR WIDE

ADHESIVE

PINCHWELD

GLASS

COMPRESSED ADHESIVE e.g. 3 mm

WK4Z or WK24Z BLADE

SMALL SPACE

NO ACCESS FOR CUTTING

BLADE FROM OUTSIDE

(A) (B)

BLADE

PINCHWELD

BUTYL

GLASS SLIDES

OUT OF MOULDING

GLASS

APPLIED

MOULDING

WK16

BLADE

APPLIED

MOULDING

GLASS

BLADE FLEXES

AND FOLLOWS

CONTOUR OF

GLASS SUFACE

PINCHWELD

2.2.3 Removing Glass Fitted With Applied Mouldings

When expensive or unremovable bonded mouldings are present, always carry out the normal internal cut of glass, then apply one of the following steps:

1. Cut from inside the vehicle and release 100% of the glass.

2. (A) Lift glass out with mouldings still attached to glass OR (B) slide glass out of the moulding using WK16 blade. See Diagram S.

For encapsulated mouldings, refer to 2.2.7 Encapsulated Glass Removal using Reverse 'R-S' and 'VR-S' Standard Blades (page 10), and Diagram U.

2.2.2.1 EXTRA HARD AND / OR WIDE ADHESIVE

When cutting extra hard and/or wide adhesives, make sure blades are sharp and cutting lubrication is regularly applied especially where adhesives are hidden below dashboard areas. With the tool and blade operating in a straight line, apply the tip of the blade directly at the adhesive and combine weight of tool with a quick jabbing action, move from left to right over a short distance, progressively cutting through the adhesive. Ensure separation is complete before moving on to next section. (Refer Diagrams M, Q and Diagram R, and section 4. Hints, Tips and Operating Techniques (page 14) ).

Do not force blades deep into adhesive or unnecessary jamming may result and tool will shut down by overload protection.

Remember to allow the power tool and blade cutting tip to OPERATE CONTINUOUSLY while cutting all adhesives.

2.2.2.2 REMOVING GLASS WHERE GLASS AND ADHESIVE IS COMPRESSED CLOSE TO THE PINCHWELD

When cutting compressed adhesive (instead of using the serrated section of the blade), use the cutting tip of a very sharp standard blade to progressively cut adhesive. This always provides success where wire and most other methods fail or may break the glass. Refer to Diagram Q, Diagram R and Diagram Y.

Diagram Q

Diagram R

Diagram S

2.2.4 Flexible Blades for Curved Glass

The cutting tips of exible blades are ground thinner and longer allowing the blade to ex and reciprocate against the curvature of the glass, panel or controller arm. Also refer to Diagram V.

Diagram T

2.2.5 Undamaged and Risky Glass Removal

The power and speed of the tool provides a safe, powerful cutting action when needed, or a gentle and precise cutting action for delicate work. Plan removal and refer to section 2.2 CUT-OUT PLANNING & GUIDELINES (page 7).

When operating in high risk areas or corner regions, or removing undamaged laminated glass, always complete cutting of easy to get at sections rst which will reduce stress to the glass allowing safer access for cutting risk areas and total separation. Always allow the tool and blade to do the cutting and do not create leverage or force the blade into adhesive, which may cause pressure points. Do not attempt to push / force the glass out until the cut out is 100% complete. You may carry out a nal check with a hand held blade to ensure separation.

2.2.6 Removal of Cracked or Badly Damaged Laminated Glass

To overcome the diculties of cutting wire and narrow cutting tips of cold knife blades consistently catching on cracks in the uneven underside surface of an extensively damaged laminated glass, use Standard blades either from inside glass (or outside if possible) with their wide and at cutting tips to eectively cut against the surface.

9© BTB Auto Glass & Body Shop Tools

2.2.7 Encapsulated Glass Removal using Reverse 'R-S'

GLASS

PINCHWELD

ADHESIVE

ENCAPSULATED

MOULDING

FLAT SIDE OF ORANGE OR BLUE

REVERSE BLADE AGAINST PINCHWELD

CONTROLLER

CAP

CONTROL ARM UNDER BLADE

PROTECT / REMOVE

PILLAR TRIM OR

HEADLINER

PINCHWELD

GLASS

WK11CW CONTROLLER ARM

UNDER BLADE. WHEEL

STOPS AT ADHESIVE

ENCAPSULATED

MOULDING

SPACE CAN

BE FILLED BY

ADHERING

VELCRO® TABS

TO WHEEL.

ADHESIVE

PANEL

TRIM

FLEXIBLE REVERSE

ORANGE / BLUE

BLADE

ENCAPSULATED

MOULDING

DAMAGED GLASS DAMAGED GLASS

(A) Cut from inside with standard blade and also cut o bottom of encapsulated mould.

(B) Pre-cut away (or cap) moulding then use Power Cold Knife blade and cut from outside.

ADHESIVE

PINCHWELD

GLASS

ADHESIVE

PINCHWELD

(2)(1)

(3)

GLASS

‘A’ PILLAR

EXPOSED EDGE GLASS

ADHESIVE

INTERNAL

TRIM

FROM OUTSIDE, CUT WITH FLAT SIDE OF BLADE AGAINST (a) GLASS OR (b) PANEL / PINCHWELD

EASY ACCESS FOR POWERED COLD KNIFE BLADE

CUT FROM INSIDE IF GLASS EDGE IS TOO CLOSE TO PINCHWELD OR IF ADHESIVE IS TOO FAR FROM GLASS EDGE

(b)

FOR ENCAPSULATED GLASSES USE YELLOW BLADE (WITH FLAT SIDE DOWN) TO CUT AGAINST PINCHWELD

(a) CUT AGAINST GLASS WITH

REVERSE "Z" BLADE (FLAT SIDE UP)

ACCESSIBLE GLASS EDGE

WIDE

DIFFICULT

ADHESIVE

REVERSE ZR-S 'R' BLADE HAS

FLAT SIDE OF CUTTING TIP UP

‘A’

PILLAR

TRIM

ORANGE

WK4ZR-S or

WK24ZR-S BLADE

And Reverse 'VR-S' Standard Serrated Blades

a. When using ORANGE and BLUE reverse serrated blades

for precision cutting against pinchwelds, as per Diagram U operate at approximately 45° to 90° and pull in a sideways or backward sawing motion utilising the serrated edges of the blade cutting tip, as per Diagram Q.

b. Use caution when operating ORANGE and BLUE reverse

serrated blades close to headliners or pillar / trim panels. If required, protect or remove interior trims or headliner. Also see Diagram U.

c. When using 'R' blades, always use a controller arm between

the glass and blade.

Diagram U

Diagram W

2.2.8 Exposed or Bare Edged Glass

Exposed and/or bare edged glass allows many eective and safe solutions using BTB's range of blades for cutting either against the glass or against the pinchweld while operating from outside of a vehicle. See Diagrams N, X and Diagram Y.

2.2.7.1 REMOVAL OF ENCAPSULATED GLASS FOR RE-INSTALLATION

For safe removal of undamaged encapsulated glass it is necessary most times to use BTB’s specially designed reverse bend 'R-S' (orange) and 'VR-S' (blue) blades to cut against the pinchweld or car body, and NOT against the glass , OR for long reach, turn over the WK1-S or WK2-S long straight blades to again place the at side of the cutting tip against the pinchweld and cut safely underneath the

encapsulation. Refer to Diagrams P, U, V and Diagram X(3).

Controller arms should be tted underneath 'R-S' AND 'VR-S' blades to support and steer the blade against the pinchweld and away from encapsulated glass, but also precisely control the depth of blade penetration. Refer to Diagram U and Diagram V.

2.2.9 Cutting from Outside the Vehicle with Standard Flat Blades Or 'ZR-S' Blades

Using an Orange reverse 'ZR-S' blade or standard at blade, with at side facing the surface you want to cut against, is a good alternative to using a Powered Cold Knife blade when cutting from outside the vehicle where the adhesive is hard and / or too wide for a Powered Cold Knife blade. Refer to Diagram P, Diagram X(3) and Diagram Y.

Diagram V

2.2.7.2 REMOVAL OPTIONS FOR UNUSABLE / DAMAGED ENCAPSULATED GLASS

(A) Use a Standard blade to cut o bottom of encapsulated mould

(B) Cut away (or cap) moulding using a winged WK6 pinchweld

blade or desired method then use a Powered Cold Knife blade to cut between moulding and glass.

Also refer to options shown in Diagram X.

10 © BTB Auto Glass & Body Shop Tools

Diagram X

Diagram Y

2.2.10 Cutting from Outside Vehicle with a Powered

Powered

Cold Knife

Blade

WK27 tip faces left

WK28 tip

faces right

WK27 tip faces left

WK28 tip

faces right

Forward OR Backward

GLASS

Keep Blade at 90°

To Glass Surface

Always Operate Blade Parallel with Glass Edge

Incorrect Blade Angle May Cause Blade or Glass Breakage

0.5 or 1.0 mm of adhesive will remain

for re-bonding

Pinchweld

Adhesive

Trim Panel

Pull adhesive

away as shown

Wings protect painted

pinchweld wall and interior

trim, allowing adhesive to

steer blade

Underside radius on cutting edge

extends up vertical wings to avoid

scratching paintwork.

WK6-S

Cutting Tip Widths:

15mm

WK6-L

25mm

WK6-M

20mm

WK6-40 (Flat)

40mm

Pinchweld

Scraper

Blade

Cold Knife (PCK) Blade

2.2.10.1 GUIDELINES FOR USING WK27 & WK28 POWERED COLD KNIFE BLADES

First refer to Diagrams X(3), Z and W.

The most eective method for using PCK blades with the E-Tool is to push the blade in a forward motion. However, pulling the blade is optional, allowing many more valuable benets, refer item h. below.

a. Select the PCK blade best suited to the task.

i. The WK27 (blade tip facing left) and WK28 (blade tip

facing right) PCK blades are available in optional cutting tip lengths, 'S' Short 19mm (¾"), 'M' Medium 25mm (1"), 'L' Long 30mm (1¼") and 'XL' Extra Long 45mm (1¾"). The 'L' blade has a taller prole servicing situations where the vehicle A-pillar or pinchweld wall is excessively high.

ii. YELLOW WK27 and WK28 blades operate (in the same

manner as a manual cold / pull knife) from the outside of exposed or bare edge glass and will hug and cut adhesive against the internal side of glass surface. They

can also be used from inside vehicle on selected installations (e.g. encapsulated glass) to cut against the

pinchweld.

iii. The ORANGE reverse PCK blades are also used from the

outside for removing undamaged encapsulated glass but with at side down, to cut against the pinchweld. Refer to Diagram A (right diagram) on page 2.

b. Apply protective tape to the vehicle paintwork if necessary.

c. Ensure that blade cutting edges are sharp at all times.

d. If required, cut any excess adhesive away from the glass

edge using a WK5 or WK5-S blade in manual handle.

e. Fit required length WK27 or WK28 blade into the power tool.

f. Regularly spray cutting lubrication to the immediate

cutting area. Apply to both outside and inside of the glass if possible.

g. Similar to a manual cold knife, identify an accessible entry

point for the blade and insert blade tip under the glass edge. If necessary, turn power tool to low to assist entry under glass. If it is dicult to enter the blade then use a standard blade (see Diagrams E and N) to cut a corner section from the inside, which allows the glass to ex away slightly and for insertion of a PCK blade. Do not apply excessive pressure or force to the blade.

h. Alternatively, the E-Tool's FIXED, fast, short reciprocal stroke

also allows the PCK blade to be entered/started at the bottom of an 'A' pillar (below the guard or bonnet/hood) and pulled in a backward direction (up the 'A' pillar).

i. If the adhesive is extremely hard to cut or the glass edge is

too close to the pinchweld with possible risk of contact with vehicle paintwork, it is recommended to use BTB’s internal blade cutting method or a combination of both. Refer to

Diagram X (2)

2.2.10.2 CORRECT BLADE & TOOL ALIGNMENT FOR EFFICIENT CUTTING USING PCK BLADES

Refer to DiagramZ.

a. Do not force or twist PCK blades. Align the power tool and

blade tip parallel to the glass, spray cutting lubrication and steer the blade along the line of the glass edge. For best results allow the reciprocating action of the power tool to do the work whilst applying light pressure to steer the blade in a forward or backward motion.

b. When cutting hard adhesive, regularly spray lubrication to

the cutting areas on outside and inside of glass if possible.

c. If cutting wide adhesive bands, always use a short cutting

tip rst (19mm), then a longer version (25mm or 30mm) to complete the cut out.

Diagram Z

d. Do not force the blades. If the blade is not cutting:

i. Blade is not sharp or is being held at the wrong angle to

the glass, OR

ii. Adhesive is too wide, hard or close (see Diagrams R, Y).

Consider combining the cutting from inside with a Standard blade and outside with a PCK blade as a solution for dicult removals.

f. The WK27 and WK28 blades may also be used in the WK7 or

WK7L manual handles (supplied with toolkits) for use on soft or small amounts of adhesives.

2.2.11 Pinchweld Trimming With No Damage to Paintwork

BTB’s WK6 range of 'winged' pinchweld scraper blades are for safely trimming excess adhesive from pinchwelds and have a special and distinct radius grind cutting edge to the underside extending up the vertical wing on each side, which avoids any damage to painted pinchwelds. These blades are normally used in the WK7 or WK7L manual handles but can also be used in the power tool for heavier duty tasks such as removal of body deadener, soundproong or seam sealer. Use with yellow label side facing upward. Refer to Diagram ZA.

Diagram ZA

11© BTB Auto Glass & Body Shop Tools

2.2.12 Backll Adhesive Removal (Bus & Train Glasses)

ADHESIVE

GLASS

GLASS EDGE

BUS OR

TRAIN

PANEL

FLAT SIDE OF WK5 or WK5S

BLADE MUST FACE GLASS

FOR 1st AND 2nd CUT

OPERATE AT 45° TO GLASS FOR BOTH 1st AND 2nd CUT

WK11DW5

CONTROLLER ARM

1st cut

2nd cut

GLASS

WK26

Controller

Arm

Body panel

WK17 Blade

Adhesive

Glass

Adhesive backll being removed

Adhesive in

divisional joint

WK26

Controller

Arm

WK26

Use a rat tail (round) le to

sharpen radiused side

When the glass edge is surrounded by adhesive backll, a separation from the glass edge must be created prior to the cut out procedure. The two options for removing backll are outlined next. Refer to Diagram ZB and Diagram ZC.

2.2.12.1 REMOVING BACKFILL USING A WK5-S BLADE

1. Fit a WK5-S or WK5 blade and WK11DW5 controller arm to the power tool with at side of blade facing controller arm wheel.

2. Apply the rst cut with the at side of the blade against the glass edge operating at approximately 45°. The controller arm wheel rolls along the glass to control the blade’s cutting depth.

3. To create the V cut, remove the blade from the tool, turn it over and ret it. Flip the tool over so that the at side of the blade still faces the glass.

4. Apply a second V cut in the backll to expose the glass edge, again operating at approximately 45°. The controller arm wheel rolls along the panel edge to control the blade’s cutting depth.

Refer to Diagram ZB below.

2.3 Bonded Panel & Glass Roof Removal

2.3.1 Bonded Panel & Roof Module Frame Removal

Bonded panel removal and complete roof module removal (including frame) are similar to glass removal in many ways. You need to study & plan your removal technique:

• Choose whether to cut against the bonded panel or against the vehicle frame.

• Select the appropriate blade that will place the at side of the blade toward the surface you want to cut against.

• Decide if a depth control arm is required.

• Cut all easily accessible areas rst.

• If space to enter a blade between the frame and panel is small

due to a thin layer of adhesive, use the tip of the blade and the tool's reciprocal stroke to jab in and out to progressively cut the adhesive.

• To reduce compression or pressure and allow faster cutting of adhesive, progressively pull and ex the panel away, or insert a lever/wedge or another blade to the adhesive area already cut.

Where bonded panel removal diers from glass removal:

• Panels are not subject to cracking/breaking

• Most panels can be exed/peeled away as cutting progresses

• Panels are often lapped and bonded on top of another. Again,

this requires systematic and progressive separation as described above.

Diagram ZB

2.2.12.2 REMOVING BACKFILL USING A WK17 CHANNEL BACKFILL BLADE

Also refer to Diagram A on page 2.

2.3.2 Panoramic Glass Roof Removal (See also 2.3.1)

Panoramic glass roof is similar to glass removal in many ways:

• Refer to the hints and tips provided throughout this user manual.

Diagram ZC

1. Always use a WK26 controller arm when using a WK17 channel backll blade to keep the power tool and blade parallel to the glass surface and regulate cutting depth.

2. Blades must be kept very sharp. Use a small rat-tail le to sharpen the radiused side of the blade.

3. The backll blade is cut so that it will naturally dig in to create a U-Shape cavity around the glass edges. Do not force or twist the blade.

4. With the E-Tool, the backll blade can be pushed or pulled along the backll.

• Removal of a glass roof or roof module generally require a combination of cutting from inside vehicle and from the outside, leveraging and wedging to reduce compression if needed. Use depth control arms where required, and NOTE: Cutting lubrication is very important. Refer to Section 2.1.5 Cutting Lubricant Is Important (Page 6).

• When cutting against softer material frames or panels (e.g. aluminium, breglass, plastic), use of a double bevelled V (green) or VR-S (blue) safety edge blade is recommended.

Diagram ZD

Diagram ZE

2.4 Removing Side Mouldings & Emblems

PANEL

RECESS

MOULDING

PANEL

WIDE

MOULDINGS

STANDARD

BLADE

SPADE BLADE

MOULDINGS ON FLAT PANELS

MOULDINGS ON

CONCAVE PANELS

MOULDINGS ON RECESSED PANELSBADGES AND

NAMEPLATES

WK1

LONG FLAT

BLADE

WK24ZV

BLADE

WK4Z,

WK18Z or

WK19Z

SPADE BLADE

WK4Z,

WK18Z or

WK19Z

SPADE BLADE

SMALL

MOULDINGS

1st cut

2nd cut

BLADE

STEEL GUIDE

CONE POINT BLADE CHUCK SCREW (For CUTTING blade use)

FLAT NOSE RETAINING SCREW (For powered hack saw blade use)

Quickly and safely remove adhesive tted decorative mouldings, emblems, badges and rear spoilers without causing damage to moulding, spoiler or painted surface. Use blade similar to auto glass removal but always with the at side of the blade operating against the lubricated painted panel surface. BTB recommends using nonserrated WK18Z and WK19Z Spade Blades where possible on at panels. Blades can be used in the Power Tool or WK7 manual handle.

NOTE: Do not use serrated blades for badge/moulding removal.

NOTE: Using cutting lubrication with cutting blades is very important to avoid damage to painted surfaces. Refer to Section

2.1.5 Cutting Lubricant Is Important (Page 6).

To remove mouldings from at panels, operate the at side of the blade against the panel surface.

To remove mouldings from recessed panels start from one end using a WK1 long straight blade and work along the panel surface, progressively separating the moulding from the panel.

2.5 Using the Tool as a Power Hacksaw

To convert the tool into a power hacksaw:

1. Turn o and disconnect the tool from the battery to avoid accidental injury.

2. Remove the cone point blade chuck screw in tool chuck.

3. Insert the power hacksaw blade and blade guide.

4. Fit the at nose retaining screw and tighten.

5. Reconnect the tool to the battery and operate as normal.

Diagram ZF

Diagram ZG

3. Troubleshooting

Behaviour Possible Reason Action

Blade noise, vibration or apping

Blade keeps coming loose in chuck

Inecient cutting

Tool won't start

Tool stops, red LED lit continuously

Tool stops Power cord is unplugged

Tool stops Tool is accidentally

Tool stops SPB33 Cone Point Blade

Tool repeatedly stops, red LED blinks

Tool repeatedly stops

Lack of power Tool is on low speed

Using incorrect blade or blade angle or cutting action.

Flat Nose Grub Screw (for hacksaw blade) has wrongly been used in

Refer to Diagram J and Diagram K for cutting technique.

Fit the correct SPB33 Cone Point Blade

Chuck Screw. place of the Cone Point Blade Chuck Screw.

Cutting lubrication not being used

Use either plain

water or adhesive

manufacturer

approved cutting

lubricant

Blade not sharp. Sharpen blade.

Tool on low speed. Switch to high speed.

Trying to cut hard/wide adhesive in one pass or forcing the blade into the adhesive.

Controller cap screw (SPB32) protruding and jamming chuck.

Blade chuck screw SPB33 loose and jamming on

Keep blade and

tool operating

continuously and at

maximum speed.

Incorrect screw used

to replace SPB32; use

correct screws.

Ensure SPB33 is rmly

screwed in at all times. controller cap body.

Battery is at, indicated

Charge the battery. by solid red LED on tool.

Tool-Battery connectors

Check all connections. are loose.

Speed control switch is in o (0) position.

Press speed control

switch to low (I) or

high (II) position.

Charger may not be charging battery

Low Battery or battery needs replacing

Test tool power using

another 12V battery

Recharge or replace

battery.

Check external and or not fully inserted, or terminals are loose inside battery bag.

internal battery bag

connections are

properly seated.

Check speed control turned o.

switch is in the high or

low position.

Whenever tool is Chuck Screw is loose and jamming in controller cap.

running, always ensure

that chuck screw is

tight, with or without

blade inserted in tool.

Overloading from jamming blade in hard/ wide adhesive, which activates shutdown feature.

Tool is set on low speed

Lubricate cutting area

regularly.

Reduce the amount of

overload force being

applied.

Switch to high speed. setting which may activate overload shut down.

Switch to high speed. setting.

4. Hints, Tips and Operating

COMPLETE

CONTROLLER CAP

ASSEMBLY

(Incl. CAP, 2 x SPB32)

CONTROLLER

CAP SCREW

CONTROLLER

CAP PARTS

LAYOUT

(parts not

available

separately)

#SPB34K

2 x #SPB32

CONE POINT

BLADE

CHUCK SCREW

#SPB33

Techniques

4.1 Standard Blades (Including Serrated Blades)

1. Select a blade type and colour that allows the at side of the

blade to hug the surface you want to cut the adhesive away from.

2. When the at side of a YELLOW or GREEN blade tip is against

glass it will always cut close to the glass surface.

3. When the at side of an ORANGE 'R' or BLUE 'VR' (reverse)

blade tip is against the pinchweld it will always cut close to the pinchweld, away from encapsulated mouldings, heater elements or sensors.

4. Standard (non-serrated) blade tips cut adhesive with a

reciprocating (in and out) action with the tip of the blade jabbing in and out of the adhesive bead, rather than a sawing action.

5. Serrated blades should be operated at approximately 45o to

90° to the adhesive in a sideways or backward sawing motion. Use caution when operating reverse (ORANGE) blades close to headliners or trim panels and use headliner protection methods.

6. Do not force the blade deep into adhesive. It is more eective

for the power tool to operate continuously while progressively steering the blade back and forth along a short section.

7. On dicult removals, always cut the easy-to-get-at areas rst.

This will release pressure on the glass and provide easier access to the dicult areas, resulting in a faster cut-out.

8. Do not use long blades when a short blade will do. A short blade

brings the blade cutting tip closer to the nylon controller cap, resulting in faster and more precise cutting of the adhesive.

9. If a blade is not cutting eciently, is apping against the glass or

is making excessive noise, the tool and blade are being held at an incorrect angle and/or the wrong blade is being used.

10. For ecient cutting and to avoid heat build up, ensure blades

are sharp. Also ensure the cutting area is regularly lubricated with an appropriate cutting uid, to both inside and outside glass surfaces if possible.

11. To overcome the diculties of cutting wire and small cutting

tips consistently catching on cracks in the uneven surface of a damaged laminated glass, use Standard blades with their wide and at cutting tips to eectively cut against the surface.

12. When cutting from inside the vehicle, the nylon controller cap

should be held against the glass surface wherever possible. It will not scratch the glass or painted panel and will steer the blade tip to the correct cutting angle.

13. Use adjustable cutting depth controller arms to avoid causing

damage to the painted body panel, mouldings or blade. When using Orange or Blue Reverse blades, always use a control arm between the glass and blade See Diagrams H, U and Diagram V.

14. Adhesive Velcro® protection pads (included in BTB kits) can be

tted to blades to protect the glass surface and painted panels.

15. Plastic locator pins, Velcro® pads or bolts are often used in

addition to adhesive when a glass is installed. Use a blade to pre-cut plastic pins or Velcro®. When cutting around steel bolts or pins, to avoid blade damage, mark the location of bolts/ pins with masking-tape, then carry out a normal cut out while working as close as possible around the pin. Use blades in a manual handle to nish around dicult areas.

16. To retain thumb on trigger of E-Tool when switching from

the left side to right side, refer to section 2.2.1.4 Cutting Below Dashboard while Standing in Doorway (page 8).

4.2 Powered Cold Knife Blades (WK27 and WK28 Blade range)

1. Do not force the Powered Cold Knife (PCK) blades. Align

the power tool and blade tip parallel to the glass. Allow the reciprocal action to do the work. The recommended and most eective method for using PCK blades with the E-Tool is to push the blade in a forward motion. Where pushing is not possible refer to section 2.2.10.1.h. Always apply cutting lubrication, ensuring the leading edge of blade tip is hugging the glass surface. Refer to Diagram Z for WK27 and WK28 usage instructions regarding correct angle of blades. If cutting wide adhesive bands, always use the shortest cutting tip rst, then a longer version to complete the cut out.

2. To create a starting point for a PCK blade, a combination of

inside and outside cutting can be the most eective. e.g. From inside, rst cut a small section at a corner, which allows entry for the PCK blade from outside. For windshield removal, the PCK blade can also be operated in a pulling motion, allowing these blades to be entered/started at the bottom of an 'A' pillar (below the guard or bonnet) pulling in a backward direction (up the 'A' pillar).

3. Performance will be reduced if the blades are not sharp or

spacing between the glass and pinchweld is minimal.

5. Tool Repair & Part Replacement

For all other problems contact your nearest BTB Distributor or your nearest Authorised BTB Repair Agent. Do not try to repair the tool yourself. Opening the tool up will void your warranty.

For additional tools or replacement controller caps contact your place of purchase.

6. Spare Parts

Diagram ZH

Note:

• The controller cap assembly on the BTB E-Tool and BTB WK10HD

air tool is identical / interchangeable

• Other controller cap assembly parts are not available individually

(e.g. screws, nuts, springs etc.)

• For replacement batteries, bags, tools, blades and kits contact

your nearest BTB supplier.

WK18ZS

WK19ZS

7. Blade Chart

WK18Z

Standard Blades

Y = Yellow

O = Orange

G = Green

B = Blue

Group Part

Straight

Blades

(YELLOW

GREEN)

WK1 Y 300

WK1-S Y 300

WK1X Y 370

WK1ZX Y 370

WK2 Y 240

WK2-S Y 240

WK2V-S G 240

WK5 Y 130

Flat Side Down

Bent Blades

(YELLOW)

WK5-S Y 130

WK3 Y 190

WK3-S Y 190

WK4 Y 190

WK4-S Y 190

WK24 Y 240

Flat Side Down

Z Blades

(YELLOW

GREEN)

WK24-S Y 240

WK4Z Y 140

WK4Z-S Y 140

WK4ZV-S G 140

WK24Z Y 150

WK24Z-S Y 150

WK24ZV G 150

Flat Side Down

'R' (Reverse) Z Blades

(ORANGE OR BLUE*)

WK24ZV-S G 150

WK4ZR-S O 140

WK4ZVR-S B 140

WK24ZR-S O 150

WK24ZVR-S B 150

Flat Side Up

WK4R-S O 190

WK24R-S O 240

* Orange and Blue blades have cutting tips opposite to

Yellow and Green blades. Note proles shown.

BLADE SPECS

Colour

Serrated

Flexible

Spade Blades (40mm Wide)

Group Part

Spade

Blades

WK18Z Y 140

WK18Z-S Y 140

WK19Z Y 180

WK19Z-S Y 180

Colour

Serrated

Flexible

Length

(mm)

Controller Arm

WK11EW

N/A

WK11FW

WK11DW5

WK11FW

WK11AW / WK11BW5

WK11CW

Controller Arm

WK11AW / WK11BW5

IN KIT

ETK12STR

ETK12CLS

ETK12TEC

Pinchweld Scraper Blades

IN KIT

Group Part

Pinchweld Scraper Blades

WK6-S 15

WK6-M 20

WK6-L 25

Width (mm)

ETK12STR

ETK12CLS

ETK12TEC

Winged

WK6-40 40

WK6-25 25

Flat

WK6-15 15

Powered Cold Knife Blades

Controller Arm

WK11PP

IN KIT

ETK12STR

ETK12CLS

ETK12TEC

WK27

Blade tip

faces left

WK28

Blade tip

faces right

Y = Yellow

O = Orange

Group Part

PCK Blades (YELLOW REGULAR GRIND)

WK27S Y 19

WK27M Y 25

WK27L Y 30

WK27XL Y 45

WK28S Y 19

WK28M Y 25

Flat Side Up

WK28L Y 30

WK28XL Y 45

'R' (Reverse)

Blades

(ORANGE*)

Flat Side Down

WK27RM O 25

PCK

WK28RM O 25

Colour

Length (mm)

Cutting Depth Controller Arms

WK11AW Use over YELLOW 'Z'

blades and WK3 & WK4 blades. Roller Wheel will roll along urethane bead to control cutting depth

WK11BW5 Use over YELLOW 'Z' blades and WK3 & WK4 blades. Roller Wheel will roll along A-Pillar or vehicle trim to control cutting depth

WK11CW Use under ORANGE blades for safe encapsulated glass removal. Roller Wheel rolls along urethane bead to control cut depth.

WK11DW5 Use under WK5 & WK5-S blades for removing backll on bus & train glasses

WK11EW Use over YELLOW WK1 & WK1-S long blades for cutting below dashboards and where long reach depth control is required.

WK11FW Use long end over YELLOW WK2, WK4 blades or under ORANGE WK24R-S. Use shorter end over YELLOW WK3 blades.

WK26 Use beside WK17 backll removal blades. The nylon guide runs along glass surface to steer the blade and regulate cutting depth.

WK11PP Use with WK27 & WK28 powered cold knife blades between blade and pinchweld wall to avoid contact with paintwork.

WK26

The data contained in this catalogue is correct at the time of publication, however BTB and their suppliers take no responsibility for omissions or errors.

Distributor:

BTB AUTO GLASS & BODY SHOP TOOLS

DIV OF BTB AUTOMOTIVE PTY LTD – ABN 41 098 604 954 ACN 098 604 954

1b Wood Street, Bendigo Victoria 3550, AUSTRALIA

Telephone: (03) 5443 1755 Sales: (03) 5442 8833 International Phone: + 61 3 5443 1755 Facsimile: (03) 5441 5263 International Fax: + 61 3 5441 5263 Toll Free: (Aust Only) 1 800 032 166 E-mail: sales@btbtools.com Web: www.btbtools.com

2014-03

BTB ETS1200 E-Tool User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual