www.wackergroup.com
Floor Saw
BFS 1318AS
BFS 2002AS
OPERATOR’S MANUAL
0162594en 001
0207
0 1 6 2 5 9 4 E N
0162594en 001
0207
www.wackergroup.com
CONCRETE SAW
BFS Series
Rev. 02/07
PAGE INTENTIONALLY LEFT BLANK
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Table of Contents
1. Foreword.....................................................................................................................3
2. Safety Information......................................................................................................4
2.1 Operating Safety........................................................................................5
2.2 Operator Safety while using Internal Combustion Engines....................... 6
2.3 Service Safety...........................................................................................7
2.4 Hazard Symbols........................................................................................8
2.5 Damage Prevention Messages..................................................................9
2.6 Safety Labels.............................................................................................9
3. Saw Features............................................................................................................10
3.1 Blade Drive System.................................................................................10
3.2 Depth Indicator.........................................................................................10
3.3 Tach / Hourmeter.....................................................................................11
3.4 Water System..........................................................................................11
3.5 Saw Dimensions......................................................................................11
4. Unpacking, Assembly and Preparation.................................................................12
4.1 Initial Servicing.........................................................................................12
4.2 Engine Preparation..................................................................................12
4.3 Battery Preparation..................................................................................13
4.4 Hydrostatic Transmission.........................................................................13
4.5 Mounting the Blade................................................................................. 14
4.6 Front Pointer Alignment...........................................................................14
5. Saw Operations........................................................................................................15
5.1 Description of Controls......................................................... ...................15
5.2 Description of Controls......................................................... ...................16
5.3 Operation in Enclosed Areas...................................................................16
5.4 Engine Starting Procedures.....................................................................16
5.5 Maneuvering the Saw..............................................................................17
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Table of Contents
5.6 Wet Cutting..............................................................................................18
5.7 Dry Cutting...............................................................................................18
5.8 Aligning the Saw with a Marked Line.......................................................19
5.9 Starting a Cut...........................................................................................19
5.10 Sawing a Straight Line.............................................................................20
5.11 Finishing a Cut.........................................................................................20
5.12 Cutting with the Blade on the Left Side....................................................21
5.13 Blade Speed and Throttle Setting............................................................21
6. Maintenance.............................................................................................................22
6.1 Cleaning.................................................................................................. 23
6.2 Engine Maintenance................................................................................23
6.3 Grease Points..........................................................................................23
6.4 Controls...................................................................................................24
6.5 Hydrostatic Transmission........................................................................24
6.6 Drive Chain..............................................................................................24
6.7 Friction Drive Wheels Adjustment............................................................24
6.8 Neutral Adjustment..................................................................................24
6.9 V-Belts.....................................................................................................25
6.10 Electrical System.....................................................................................26
6.11 Battery.....................................................................................................26
6.12 Depth Control...........................................................................................26
6.13 Water System..........................................................................................26
7. Troubleshooting.......................................................................................................27
8. Service Record.........................................................................................................28
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Engine exhaust, some of its constituents, and certain vehicle
WARNING
components contain or emit chemicals known to the State of
California to cause cancer and birth defects or other reproductive
harm.
1. Foreword
This manual provides information and procedures to safely operate
and maintain this Wacker model. For your own safety and protection
from injury, carefully read, understand and observe the safety
instructions described in this manual.
Keep this manual or a copy of it with the machine. If you lose this
manual or need an additional copy, please contact Wacker
Corporation. This machine is built with user safety in mind; however,
it can present hazards if improperly operated and serviced. Follow
operating instructions carefully! If you have questions about operating
or servicing this equipment, please contact Wacker Corporation.
CALIFORNIA
Proposition 65 Warning:
The information contained in this manual was based on machines in
production at the time of publication. Wacker Corporation reserves
the right to change any portion of this information without notice.
All rights, especially copying and distribution rights, are reserved.
Copyright 2007 by Wacker Corporation.
No part of this publication may be reproduced in any form or by any
means, electronic or mechanical, including photocopying, without
express written permission from Wacker Corporation.
Any type of reproduction or distribution not authorized by Wacker
Corporation represents an infringement of valid copyrights and will be
prosecuted. We expressly reserve the right to make technical
modifications, even without due notice, which aim at improving our
machines or their safety standards.
Revision 03/05/07 BFS SERIES
5
Safety Information
WARNING
DANGER
CAUTION
2. Safety Information
This manual contains DANGER, WARNING, CAUTION, NOTICE and
NOTE callouts which must be followed to reduce the possibility of personal
injury, damage to the equipment, or improper service.
This is the safety alert symbol. It is used to alert you to potential
personal injury hazards. Obey all safety messages that follow this
symbol to avoid possible injury or death.
DANGER indicates an imminently hazardous situation which, if not
avoided, will result in death or serious injury.
WARNING indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
CAUTION indicates a potentially hazardous situation which, if not
avoided, may result in minor or moderate injury.
NOTICE: Used without the safety alert symbol, NOTICE indicates a
hazardous situation which, if not avoided, could result in property
damage.
Note: Contains additional information important to a procedure.
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2.1 Operating Safety
WARNING
Familiarity and proper training are required for the safe operation of
equipment! Equipment operated improperly or by untrained personnel
can be dangerous! Read the operating instructions contained in both
this manual and the engine manual and familiarize yourself with the
location and proper use of all controls. Inexperienced operators
should receive instruction from someone familiar with the equipment
before being allowed to operate the machine.
Safety Information
2.1.1
2.1.2
2.1.3
2.1.4
2.1.5
2.1.6
2.1.7
2.1.8
2.1.9
2.1.10
2.1.11
2.1.12
2.1.13
2.1.14
2.1.15
2.1.16
2.1.17
NEVER operate this machine in applications for which it is not
intended.
NEVER allow anyone to operate this equipment without proper
training. People operating this equipment must be familiar with the
risks and hazards associated with it.
NEVER touch the engine or muffler while the engine is on or
immediately after it has been turned off. These areas get hot and
may cause burns.
NEVER use accessories or attachments that are not recommended
by Wacker. Damage to equipment and injury to the user may result.
NEVER leave machine running unattended.
NEVER tamper with or disable the function of operating controls.
NEVER use choke to stop engine.
NEVER operate the machine in areas where explosions may occur.
ALWAYS read, understand, and follow procedures in Operator’s
Manual before attempting to operate equipment.
ALWAYS be sure that all other persons are at a safe distance from
the machine. Stop the machine if people step into the working area
of the machine.
ALWAYS be sure operator is familiar with proper safety precautions
and operation techniques before using machine.
ALWAYS wear protective clothing appropriate to the job site when
operating equipment.
ALWAYS wear hearing protection when operating equipment.
ALWAYS keep hands, feet, and loose clothing away from moving
parts of the machine.
ALWAYS use common sense and caution when operating the
machine.
ALWAYS be sure the saw will not tip over, roll, slide, or fall when
not being operated.
ALWAYS turn the engine OFF when the saw is not being operated.
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Safety Information
DANGER
2.1.18
ALWAYS guide the saw in such a way that the operator is not
squeezed between the saw and solid objects. Special care is
required when working on uneven ground or when compacting
coarse material. Make sure to stand firmly when operating the
machine under such conditions.
2.1.19
ALWAYS operate the saw in such a way that there is no danger
of it turning over or falling in, when working near the edges of breaks,
pits, slopes, trenches and platforms.
2.1.20
ALWAYS store equipment properly when it is not being used.
Equipment should be stored in a clean, dry location out of the reach
of children.
2.1.21
ALWAYS close fuel valve on engines equipped with one when
machine is not being operated.
2.1.22
ALWAYS operate machine with all safety devices and guards in place
and in working order. DO NOT modify or defeat safety devices. DO
NOT operate machine if any safety devices or guards are missing or
inoperative.
2.2 Operator Safety while using Internal Combustion Engines
Internal combustion engines present special hazards during
operation and fueling! Read and follow warning instructions in engine
owner’s manual and safety guidelines below. Failure to follow
warnings and safety guidelines could result in severe injury or death.
2.2.1
2.2.2
2.2.3
2.2.4
2.2.5
2.2.6
2.2.7
2.2.8
2.2.9
2.2.10
DO NOT smoke while operating machine.
DO NOT smoke when refueling engine.
DO NOT refuel hot or running engine.
DO NOT refuel engine near open flame.
DO NOT spill fuel when refueling engine.
DO NOT run engine near open flames.
DO NOT run machine indoors or in an enclosed area such as an
enclosed room unless adequate ventilation, through such items as
exhaust fans or hoses, is provided. Exhaust gas from the engine
contains poisonous carbon monoxide gas; exposure to carbon
monoxide can cause loss of consciousness and may lead to death.
ALWAYS refill fuel tank in well-ventilated area.
ALWAYS replace fuel tank cap after refueling.
ALWAYS check fuel lines and fuel tank for leaks and cracks before
starting engine. Do not run machine if fuel leaks are present or fuel
lines are loose.
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2.3 Service Safety
WARNING
Poorly maintained equipment can become a safety hazard! In order
for the equipment to operate safely and properly over a long period of
time, periodic maintenance and occasional repairs are necessary.
Safety Information
2.3.1
2.3.2
2.3.3
2.3.4
2.3.5
2.3.6
2.3.7
2.3.8
2.3.9
2.3.10
2.3.11
2.3.12
2.3.13
2.3.14
2.3.15
DO NOT attempt to clean or service machine while it is running.
Rotating parts can cause severe injury.
DO NOT operate machine without air cleaner.
DO NOT remove air cleaner cover, paper element, or precleaner
while engine is running.
DO NOT alter engine speeds. Run the engine only at speeds
specified in the Technical Data Section.
DO NOT crank a flooded engine with the spark plug removed on
gasoline-powered engines. Fuel trapped in the cylinder will squirt out
the spark plug opening.
DO NOT test for spark on gasoline-powered engines, if engine is
flooded or the smell of gasoline is present. A stray spark could ignite
fumes.
DO NOT use gasoline or other types of fuels or flammable solvents
to clean parts, especially in enclosed areas. Fumes from fuels and
solvents can become explosive.
ALWAYS replace safety devices and guards after repairs and
maintenance.
ALWAYS keep area around muffler free of debris such as leaves,
paper, cartons, etc. A hot muffler could ignite them, starting a fire.
ALWAYS do Periodic Maintenance as recommended in Operator’s
Manual.
ALWAYS clean debris from engine cooling fins.
ALWAYS replace worn or damaged components with spare parts
designed and recommended by Wacker.
ALWAYS disconnect spark plug on machines equipped with gasoline
engines, before servicing, to avoid accidental start-up.
ALWAYS keep machine clean and labels legible. Replace all missing
and hard-to-read labels. Labels provide important operating
instructions and warn of dangers and hazards.
ALWAYS follow instructions when disconnecting fuel lines. Failure to
do so may result in fuel squirting from fuel system.
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Safety Information
on
(
(
)
)
2.4 Hazard Symbols
Symbol Meaning
EXPLOSIVE FUEL
Gasoline is extremely flammable and its vapors can explode if ignited.
Store gasoline only in approved containers, in well-ventilated, unoccupied
buildings, away from sparks or flames. Do not fill the fuel tank while the
engine is hot or running, since spilled fuel could ignite if it comes in contact
with hot parts or sparks from ignition. Do not start the engine near spilled
fuel. Never use gasoline as a cleaning agent.
HOT PARTS
Engine components can get extremely hot from operation. To prevent severe
burns, do not touch these areas while the engine is running or immediately
after it is turned off. Never operate the engine with heat shields or guards
removed.
OVER SPEED
Never tamper with the governor components or settings to increase the
maximum speed. Severe personal injury and damage to the engine or
equipment can result if operated at speeds above maximum.
ACCIDENTAL STARTS
Before servicing the engine or equipment, always remove the key and
disconnect the spark plug lead to prevent the engine from starting
accidentally. Ground the lead to prevent sparks that could cause fires. Make
sure the equipment is in neutral.
ROTATING PARTS
Keep hands, feet, hair, and clothing away from all moving parts to prevent
injury. Never operate the engine with covers, shrouds, or guards removed.
LETHAL EXHAUST GASES
Engine exhaust gases contain poisonous carbon monoxide. Carbon
monoxide is odorless, colorless, and can cause death if inhaled. Avoid
inhaling exhaust fumes, and never run the engine in a closed building or
confined area.
ELECTRICAL SHOCK
Never touch electrical wires or components while the engine is running. They
can be sources of electrical shock which could cause severe injury or burns.
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2.5 Damage Prevention Messages
G13
G17
G16
G14
G15
D15
Other important messages that are designed to help prevent damage
to your Wacker BFS Series Concrete Saw, other property, or the
environment are preceded by the word NOTICE.
NOTICE: Your Wacker BFS Series Concrete Saw or other property could
be damaged if you don’t follow instructions.
2.6 Safety Labels
The labels contain important safety information. Please read them
carefully. These labels are considered a permanent part of your saw.
If a label comes off or becomes hard to read, contact Wacker or your
dealer for replacement.
Item Location Description
C6
Top of Belt Guard Spark Plug Caution Label
C7
Top of Belt Guard Belt Tension Caution Label
C8
Top of Shaft & Belt Guard Guards in Place Caution Label
D15
G13
G14
G15
G16
G17
Top of Blade Guard Lift Guard Caution Label
Top of Console Tower Central Control Panel
Back of Console Tower Water On/Off
Back of Console Tower Engage
Back of Console Tower Disengage
Back of Console Tower Engine Stop
L19
Top of Gas Tank Hot Surface Caution Label
L20
Top of Gas Tank Refueling Warning Label
L21
Front of Gas Tank California Danger Label
L22
Top of Gas Tank Lethal Exhaust Danger Label
M7
Front Edge of Frame Hands and Feet Caution Label
Safety Information
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Technical Data
3. Saw Features
The Wacker BFS Series Concrete Saw is designed for wet or dry,
general application sawing. The heavy duty steel, one piece box
frame is precision jig welded and reinforced. This precisely reinforced
steel construction with balanced weight distribution and ergonomic
handlebars assures straight and accurate cutting as well as ease
of operations preventing fatigue. The 4-cycle air cooled engine is
located for easy access and maintenance. Each solid rubber wheel
is mounted on an axle for years of reliable use. The rear axle is rigid,
while the front axle pivots causing the blade to be lowered to the
desired cutting depth. The positive screw feed provides precision
control of the raising and lowering of the blade. The positive screw
feed control wheel and all controls are located for easy access and
visibility. The following table shows the available models and the
features that differentiate them.
The Wacker BFS-1318AS features a Honda ™ GX390 13 hp engine.
The Wacker BFS-2020AS features a Honda™ GX620 20 hp engine
with electric start and key ignition switch.
Model Engine/Blade Capacity Additional Features
BFS-1318AS
BFS-2020AS
Honda GX390 13 HP
18 blade guard
Honda GX620 20HP
20 blade guard
cyclone air filter, tach/hourmeter
electric starter, tach/hourmeter, centrifugal
water pump (optional)
3.1 Blade Drive System
The blade drive shaft pulleys are connected to both the engine and
to the frame mounted blade shaft. Matched v-belts are connected
to the pulleys providing engine power to the blade shaft. The 1 inch
diameter blade shaft is supported by two self-aligning pillow block
bearings. The uniquely designed right and left blade shaft allows for
cutting within 2 inches of any wall.
3.2 Depth Indicator
The BFS Series models include a depth feed indicator mounted
on the console, for ease of use and visibility.
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3.3 Tach / Hourmeter
A digital readout tach/hourmeter is factory installed on the BFS Series
models . When the engine is running, the display will indicate
the engine’s RPM. When the engine is shut off, the display will
switch to run time, initially in minutes, and then switching to hours
after the first hour of operation.
3.4 Water System
The water system of this saw provides water to both sides of the
saw blade from inside the blade guard. The saw includes a hose bib
hookup and water flow control valve.
3.5 Saw Dimensions
Model Dimensions (LxWxH)
Technical Data
BFS-1318AS 65 x 25 x 37
BFS-2020AS 65 x 26 x 37
Revision 03/05/07 BFS SERIES
13
Preparation
WARNING
4. Unpacking, Assembly and Preparation
Your Wacker BFS-Series has been shipped from the factory fully
assembled and requires only minimal service to insure proper
machine preparation prior to use. The following instructions should
be followed closely. Carefully remove carton, packing materials
and the Wacker BFS-Series saw from the pallet. The saw has been
thoroughly inspected and test operated before shipping and should
not require any additional adjustments prior to use. Check each item
with the illustration making certain all items are accounted for and in
good visual condition before discarding any packing materials. If
there are any missing or damaged parts, call customer service on our
toll free number: 1-(800) 770-0957 for instructions before proceeding
further. CONTENTS OF CARTON: saw, fasteners, handlebars, pointer
assembly, wrench, engine manual and operator’s manual.
For your own safety, never start engine until all assembly steps are
complete. Read and familiarize yourself with all controls and features
of this saw as shown in the illustration before beginning operations.
(Descriptions and illustrations are as accurate as possible at the
time of publication. Illustrations may include optional equipment or
accessories and may not show all models covered by this literature).
The handlebar and pointer assemblies are shipped in the carton
without attachment to the main saw frame. Upon removal of the saw
from the carton and pallet, the handlebars should be placed in their
correct mounting tube positions attached to the rear of the Wacker
BFS-Series main frame. Fasteners (3/8-16 bolts, washers, and nuts)
have been placed in the plastic owner’s tube attached to the saw with
the manual. Remove these fasteners and use them to attach the
handlebar and pointer assembly to the main frame as indicated in
the exploded drawing.
4.1 Initial Servicing
The engine must be thoroughly lubricated, and filled with fuel prior to
break-in or use. Refer to manufacturer’s instructions for details of service
for the engine. The section on Maintenance in this manual describes the
required periodic maintenance required under normal use.
4.2 Engine Preparation
Add Fuel
The engine is designed to operate on regular grade unleaded gasoline
only. Adding fuel to the tank should be accomplished only when the engine
is stopped and cool. Care should be taken to prevent spilling fuel over any
part of the console or engine.
NOTICE: The engine is not shipped with oil in the crankcase. Check
crankcase dipstick and fill with approved oil to the apppropriate level.
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Add Oil
WARNING
WARNING
O
I
L
L
E
V
E
L
C
O
L
D
To fill the crankcase with oil, place the engine level. In order for
this to be accomplished the blade must not be installed, and the
depth adjustment must be down (until the engine is level). Refer
to the manufacturer’s instructions for details on the type and amount
of oil required. Since the proper amount of oil is important for safe
operation, check the oil level of the engine each time you put fuel
in the gas tank. Remember that the engine and oil must be warm and
your saw must be on level ground to get an accurate reading.
In the event of a fuel spill do not attempt to start the engine until the
spilled fuel has been wiped up and the area is completely dry. When
filling the fuel tank do not overfill. Always leave enough area for
expansion due to environmental heating.
4.3 Battery Preparation (BFS2020AS Only)
The 12 volt battery is shipped wet and charged. Connect the battery
leads according to the following steps to ensure that power is
provided to the engines electric starter.
Preparation
4.3.1
4.3.2
Remove the front tower panel to obtain access to the battery terminals.
Connect the Positive (+) battery cable to the Positive battery terminal.
Tighten the cap screw and nut securely to assure proper electrical
contact.
When tightening the Positive (+) battery cable end, do not contact
the Negative (-) battery terminal with the wrench or other metallic
objects. This could cause an electrical short and electrical sparking
or an explosion of the battery. Be careful not to connect the battery in
reverse polarity, as this will short circuit the battery charging system,
damaging the fuse on the engine, and even resulting in the explosion
of the battery.
4.3.3
Connect the Negative (-) battery cable end to the Negative (-)
terminal. Tighten the cap screw and nut securely to assure proper
electrical contact.
4.3.4
Electric power is now available for engine starting. Secure the front
panel on the machine.
4.4 Hydrostatic Transmission
The hydrostatic transmission is factory-filled with fluid having a
viscosity equivalent to SAE 20 W 20. Check the oil level on the
expansion tank to ensure that the transmission has adequate fluid.
NOTICE: Do not overfill the expansion tank. NOTICE that the full level
line is near the bottom of the expansion tank. Overfilling will result in
rupturing the seals on the hydrostatic transmission and subsequent
mechanical damage.
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15
Preparation
WARNING
4.5 Mounting the Blade
When mounting the blade, locate the direction arrow on the blade and
install the blade in the proper orientation. The blade rotates clockwise
when viewed from the right side of the saw.
The blade must be properly fitted over the blade shaft and drive pin.
The drive pin must project through the hole in the blade and into the
flange for proper performance. When tightening the blade shaft nut
against the outside of the flange, tighten securely. Blade shaft threads
are left-hand on the right side of the saw, and right-hand on the left side
of the saw.
DO NOT operate without the proper blade guard covering the blade!
DO NOT operate the saw with the front of the blade guard raised.
Ensure that blade exposure does not exceed 180 degrees during
operation.
4.6 Front Pointer Alignment
The front pointer is set in line at the factory. However, the pointer
should be checked for proper alignment with the blade after every
use. The following are the procedures for aligning the pointer with the
blade, with the engine shut off.
4.6.1
Using a straight edge, carefully mark a line 12 feet long on a smooth
level concrete surface.
4.6.2
4.6.3
Place saw parallel to line. Lower blade and center it over the line.
With the blade centered over the line and the saw frame parallel to
the line, lower the front pointer assembly and position the pointer
over the line.
4.6.4
Finally, roll the saw along the entire length of the line. The saw
should lead off no more than 6 inches to the left in 12 feet of forward
travel. Adjust the pointer in or out if the lead-off is outside this
parameter.
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5. Saw Operations
WARNING
This section of the manual describes the operating procedures, and
safety precautions for proper use of this concrete saw. This saw is
intended for industrial applications by experienced operators. It is to
be operated in conformance with applicable federal, state and local
codes or regulations pertaining to safety, air pollution, noise, etc.
Improper use of this equipment, or improper machine alterations may be
dangerous. It is the operator’s responsibility to use this machine under
safe working conditions and to be fully aware of requirements for operator
safety. The operator must be aware of the machine’s capabilities and
limitations and follow the safety precautions in each section of this manual.
5.1 Description of Controls
All controls for saw operation are located on the console.
Operation
5.1.1
5.1.2
5.1.3
5.1.4
5.1.5
5.1.6
The raise/lower lever wheel raises the blade when rotated clockwise and
lowers the blade when rotated counterclockwise.
The raise/lower wheel lock is engaged when the knob on the right
side of the console is tightened.
The throttle control increases engine rpm from slow (idle) at the
bottom, to fast (full rpm) at the top.
The forward/reverse speed control gradually increases the saw travel
speed (up to forward, down for reverse) when moved from the central
neutral position. Always place this control in neutral before using the
engage/disengage lever or starting or stopping the engine
The transmission engage/disengage lever is engaged in the full
down position.
The keyed ignition switch turns clockwise to the ON and START
positions. The engine turns over with the switch in the START
position. Release the key after the engine starts.
raise/lower control wheel
trans. engage/disengage lever
rpm/hour gauge
on/off switch
trans.
control lever
throttle
Revision 03/05/07 BFS SERIES
depth gauge
hose bibb
choke
water control lever
17
optional pump
on/off switch
Operation
WARNING
DANGER
CAUTION
5.2 Buried or Concealed Hazards
Prior to operation of this machine the operator must determine the
existence and location of any subsurface features which may be
hazardous or could damage the equipment (i.e. electric cable, natural
gas line, etc.).
5.3 Operation in Enclosed Areas
The operator is cautioned not to use this equipment within enclosed
spaces. Exhaust from the engine in an enclosed space can cause
loss of consciousness and may lead to death. Ensure that the space
is adequately ventilated.
5.4 Engine Starting Procedures
Refer to the engine operating manual for proper engine operation.
Special precautions should be taken during the break-in period as
specified by the Engine Manual.
Pre-start checklist BFS-1318AS
5.4.1
5.4.2
5.4.3
5.4.4
5.4.5
5.4.6
5.4.7
5.4.8
5.4.9
5.4.10
5.4.11
Check engine oil level. Add oil if low.
Check fuel levels. Add fuel if low.
Check cooling air intake and external surfaces of engine. Make sure
they are clean and unobstructed.
Check that the air cleaner components and all shrouds, equipment
covers, and guards are in place and securely fastened.
Choke engine as required for cold starting.
Move kill switch to the ON position. Grasp handle of pull start rope
and pull it out a few inches until it engages. Once pull start is
engaged, pull firmly to spin engine. Once engine starts, push choke
control in. Allow engine to warm up for a few minutes at half throttle.
All sawing is done at the correct throttle setting (see the blade speed
and throttle setting table).
To stop engine, move throttle to slow position, turn kill switch to the
OFF position and wait for all engine movement to stop.
Pre-start checklist BFS-2020AS
Start with same steps from 5.4.1 to 5.4.5 then proceed to:
Check that the transmission is disengaged and in neutral. The
transmission lever must be exactly in neutral to prevent resistance
with could keep the transmission from starting.
Pull choke: choke engine as required for cold starting
Turn ignition switch to start. Once engine starts push choke control
in. Allow engine to warm up for a few minutes at half throttle. All
sawing is done at the correct throttle setting.
To stop engine, move throttle to slow position, turn key switch to the
OFF position and wait for all engine movement to stop.
DO NOT TURN OFF AT FULL THROTTLE
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Operation
WARNING
5.5 Maneuvering the Saw
NOTICE: Raise the blade as high as possible when maneuvering so that
the blade will not strike the pavement.
The blade is spinning whenever the saw is running.
The speed control lever for the hydrostatic transmission is adjusted
at the factory to provide approximately 40 ft/min maximum in forward
and 20 ft/min maximum in reverse with the engine running at full
throttle. When maneuvering, the engine needs to be at one-half
throttle or more so that the hydrostatic transmission can operate
efficiently.
When the TRANSMISSION LEVER is in NEUTRAL and the
DRIVE DISENGAGE LEVER
transmission is in NEUTRAL and the wheels are locked.
To engage the transmission push the engaging lever down on the
right rear of the console cowling. To disengage the transmission
pull the engaging lever up. When the saw is manually pushed, the
transmission must be disengaged. The transmission speed control
lever is located on the top of the console. This lever controls the
variable forward and reverse ground speed (up to 40 feet per minute)
of the saw.
is in the ENGAGE position, the
When engaging the transmission with the engaging lever, be sure the
speed control lever is at the neutral position to avoid saw movement.
5.6 Wet Cutting
The water used on the blade is to provide coolant during cutting,
and to flush the concrete cutting from the cut. The water hose bibb
is located below the throttle control on the left side of the saw. After
connecting the water supply, turn on the water at the source and use
water valve on console to control flow of water to blade. Be sure that
both sides of the blade are getting adequate flow of water. The water
control adjustment allows the operator to manually control the flow of
water to the blade during all operations.
5.7 Dry Cutting
Dry cutting blades have been specially designed for use with concrete
saws. Ensure that the blade you are using is clearly marked for dry
cutting.
NOTICE: When dry cutting, it is important to keep the air filter clean.
Check the condition of the filter at least every four (4) hours of
operation. Clean the pre-filter (wash in soapy water and re-oil) and
change the paper filter as soon as it becomes clogged. Concrete
dust is very abrasive, and will quickly damage internal engine parts,
causing loss of compression and eventual engine failure.
Revision 03/05/07 BFS SERIES
19
Operation
A
B
Saw only as deep as the specifications and job conditions require.
Remember, airflow helps to cool the blade during dry cutting.
Cutting too deep with one pass, or exerting excessive forward or
side pressure can be dangerous. Step cut in increments of 2 inches
(50 mm) or less, for the best results.
If reinforced abrasive blades are used for cured concrete it is usually
better to saw only 1 deep per pass. If deeper cuts are required, cut in
multiple passes.
Thinner Diamond Blades are especially advantageous when cutting
dry.
5.8 Aligning the Saw with a Marked Line
Refer to the figure below. Push the saw forward and approach the
marked line at an angle. Stop when the distance from the rear edge
of the saw frame to the line (distance A) and the distance from the
pointer to the line (distance B) are approximately equal. Lift the rear
wheels slightly off the ground by lifting on the handles and swing the
rear of the saw around until the pointer is on the line and the saw
frame is parallel to it. Do not tilt the saw too far forward to keep the
blade from contacting the concrete. The saw should now be aligned
with the marked line. Practice will fine tune this method. Critical to
this method of alignment is to ensure that the saw pointer is properly
aligned (see alignment procedures).
5.9 Starting a Cut
With the engine running at half-throttle, open the water valve to
full open. Check to verify that the water is flowing fully. Adjust the
amount of water flowing on the blade to a desired amount.
After adjusting the flow of water increase to proper throttle setting.
Lower the blade into the cut by slowly turning clockwise on the
depth control wheel. If the water supply is interrupted, stop cutting
immediately.
When the desired depth of cut is reached, lock the control wheel in
position with the depth control locking knob. During cutting, do not
exert excessive side pressure on the handle bars to attempt to steer
the saw. Use only enough pressure to follow the original marked line.
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Revision 03/05/07BFS SERIES
If the saw should stall for any reason, raise the blade out of the cut before
WARNING
restarting the engine!
When lowering the blade into a partially made cut, the blade must be
perfectly aligned within the cut before starting to saw again. DO NOT
force the blade into the material by lowering the blade too fast.
5.10 Sawing a Straight Line
The following items should be considered for best economy and efficiency
in sawing:
5.10.1
With the water on, engine at the correct throttle setting, and
the blade lowered, push the saw forward referring to the pointer
alignment.
5.10.2
The saw has a natural tendency to pull towards the side on
which the blade is mounted. To assure straight line cutting, apply
pressure to the appropriate handle. If excessive pressure is required
back off on the forward speed of the saw. If excessive pressure is
still required to make the saw travel straight, the saw may need to
have the arbor shaft adjusted.
5.10.3
Avoid sudden corrective actions when the saw deviates from the
intended line of cutting. Sudden and severe corrections can cause
the blade to be damaged or broken.
5.10.4
If the saw stalls in the cut, raise the blade out of the cut and check
the blade shaft nut before restarting the engine.
Operation
Always raise the blade completely out of the cut before stopping the
engine or turning off the water supply.
When sawing joints, be careful not to let the blade cut into the forms.
The forward speed of the saw, during cutting, should be regulated by the
operator. Driving the saw too fast while cutting may cause the front wheels
to lift causing the blade to cut at uneven depths.
The three controlling factors of cutting economy are: a) Depth of cut,
b) Forward speed of the saw and c) Blade cutting ability.
Experimental adjustment of these items, with respect to the specific
concrete aggregate being cut will result in the best cutting economy.
As new blades wear, the cutting ability usually improves. It is best to start
at a slow forward speed with a new blade and work up to a desired cutting
speed gradually.
5.11 Finishing a Cut
Raise the blade out of the cut by cranking the depth control wheel
counter-clockwise. Raise the blade high enough out of the cut to
clear the pavement and allow maneuvering of the saw.
Move the engine throttle to the slow position then turn the kill switch
off. Turn off the water valve.
Revision 03/05/07 BFS SERIES
21
Operation
on
WARNING
(
(
)
)
WARNING
5.12 Cutting with the Blade on the Left Side
Left side cutting can be easily accomplished by moving the blade
guard to the left hand side of the saw belt guard using the following
steps:
5.12.1
5.12.2
5.12.3
Turn kill switch to off position.
Disconnect water hose from blade guard.
Remove shaft guard from the left side of the saw frame and set
aside.
5.12.4
Remove blade guard from the right side of the saw frame and
reassemble on the left side of the saw belt guard.
5.12.5
5.12.6
Reassemble shaft guard on the right side of the saw frame.
Connect water hose to blade guard.
When attaching a blade to the left blade shaft, use the outside flange
from the right side and the left side nut
Do not operate saw with any guards removed. Turn kill switch to OFF
position to avoid accidental starts when removing guards.
5.13 Blade Speed and Throttle Setting
Since diamond blades cut best at specific rim-speeds, blades of
different diameters must be turned at different blade shaft rpm’s.
The Wacker BFS-1318AS will run either a 14 or 18 blade and the
Wacker BFS-2020AS will run a 16 through 20 blade.
Safe, efficient, economical cutting performance will occur at the
engine rpm (as read on the tachometer) stipulated on the following
chart.
The Wacker BFS-Series engine shaft to blade shaft ratio is 1:895.
DO NOT EXCEED THESE ENGINE RPM SETTINGS!
Operating saw blades at rotational speeds greater than those
recommended by the manufacturer can cause blade damage and
possibly subsequent personal injury. Never exceed 3600 rpm blade
shaft speed.
It is possible to cause overspeeding of the blade at throttle settings above
those stipulated on the above chart.
Blade Diameter Set Engine RPM to
14 full throttle (3500)
16 3200 - full throttle
18 2850 - 3300
20 2550 - 3000
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Revision 03/05/07BFS SERIES
Maintenance
on
WARNING
6. Maintenance
Periodic maintenance including cleaning, lubrication, tensioning of
drive belts, and inspection for wear and damage are routine servicing
procedures. Following the procedures as outlined in the following
table can prevent serious damage or malfunctioning of the machine
and aid in preserving the useful life of saw blades.
Before servicing the saw or engine, always turn the kill switch to the
off position.
Item Requiring
Maintenance Schedule
Maintenance
Maintenance
Operation
Check
Every 8 Hours
or Daily
Every 4 hours
25 Hours
or Weekly
100 Hours
or Seasonal
when dry cutting
Change Air
Air Filter
Hydrostatic
Filter
Check Oil
Transmission
Reservoir
Blade Shaft
Bearings
Lube Blade Shaft
Bearings at
end of operations
Pivot Bearings
Mainframe
Chain Drive Adjust
Tension
Transmission
Control
Assemblies
Battery
V-Belts Replace
Battery Check Water
Level
Engine Definitive information on engine maintenance is contained in the
Honda Engine Manual provided separately. Perform all mainte-
nance procedures as recommended by the Engine Manual.
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Revision 03/05/07BFS SERIES
Maintenance
WARNING
Shut off the engine before performing any maintenance. If the engine
must be run after a maintenance operation make sure the area is
well ventilated. The exhaust contains poisonous carbon monoxide
gas! Exposure can cause loss of consciousness and may result in
death.
6.1 Cleaning
Clean the machine daily, being careful to remove cutting dust and
slurry from the blade guard engine cooling fan and air ducts. Failure
to perform this operation may prevent smooth control of the saw.
Steam cleaning is the preferred method of cleaning.
6.2 Engine Maintenance
Engine maintenance and adjustment is necessary to keep the
saw in good operating condition. Maintenance operations include
oil changes, filter changes, air cleaner, spark plug, fuel filter, etc.
Perform all maintenance procedures as recommended by the Honda
Engine Manual provided separately.
For a new engine, it is especially important to change the oil after the
first 5 hours of operation. Thereafter, change the oil after every 100
hours of operation as per the engine manufacturer’s manual.
NOTICE: Always dispose of used engine oil and filters in a responsible
manner. Follow your community’s standards for disposing of these items.
Call your local recycling center to find out about recycling engine oil.
6.3 Grease Points
There are four (4) grease points (zerk fittings) on the
Wacker BFS-Series concrete saw.
The blade shaft bearing grease points need to be serviced at the end of
operations on a daily basis. The rest of the grease points require service
on a weekly basis (see maintenance schedule).
The two blade shaft grease points are accessed from underneath by tilting
the saw back. The raise/lower adjustment tube grease point is accessed
from the inside of tower control box.
The transmission drive spline shaft bearings are accessed from the inside
of tower control box and by raising the front of the saw to access from
underneath the frame.
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Maintenance
CAUTION
6.4 Controls
Stiff or sluggish response of controls must be corrected immediately.
Periodically clean and lubricate the throttle cable, the throttle and
choke controls. The frequency of this maintenance will depend on
the utilization rate and the amount of dust. After performing any
maintenance on controls, saw responsiveness must be checked
before the initiation of sawing operations.
6.5 Hydrostatic Transmission
The hydrostatic transmission should not normally require maintenance.
However, the hydraulic oil level in the reservoir and the cooling fan
blade must be checked frequently.
6.6 Drive Chain
Chain tension is adjusted by loosening the four transmission bracket
mounting bolts and moving the transmission up or down as required. All
nuts must be retightened after each adjustment. Excessive tension on the
drive chains will reduce chain life and should be avoided. Periodically wipe
the chain clean and relubricate with penetrating chain lubricant.
Breakage of the drive chain will result in the loss of braking friction through
the drive wheels. Perform daily checks of the drive chain. If any damage is
noted the chain must be replaced.
6.7 Friction Drive Wheels Adjustment
If the friction drive wheels DO NOT engage the rear wheels with
sufficient pressure, slippage of the rear wheels may occur. To correct
this situation, lengthen the engagement linkage by loosening the
two (2) linkage adjustment bolts. Lengthen the linkage bars a small
amount and retighten the bolts.
6.8 Neutral Adjustment
If, due to transmission control cable or other component
replacement, the transmission control system needs to be adjusted
to obtain NEUTRAL, the following procedure must be followed:
6.8.1
Stop the engine and place Drive Disengage Lever in Disengage
position.
6.8.2
Remove the belt guard. Loosen the engine mounting bolts, remove
the v-belts and slide the engine as far forward as possible.
6.8.3
6.8.4
Loosen cable clamp on transmission control arm.
Place Transmission Speed Control lever in neutral.
Revision 03/05/07 BFS SERIES
25
Maintenance
CAUTION
6.8.5
6.8.6
6.8.7
6.8.8
6.9 V-Belts
steel straight edge
Engine
Place the transmission in neutral by moving the transmission control
arm back and forth while manually rotating the transmission pulley.
When the pulley spins freely and no movement of the drive chain is
observed, the neutral position has been obtained.
Tighten the cable clamp.
Replace the v-belts and properly adjust v-belt tension by
repositioning engine and tightening the mounting bolts.
Reinstall the belt guard.
This machine is equipped with two heavy duty V-belts which are
tensioned properly at the factory. These must be re-tensioned after
the first half day of operation and periodically thereafter. Adjust to the
original tension as set at the factory, which is approximately 1/4 inch
of deflection of the center of the belt halfway between the pulley on
the motor and the pulley on the blade shaft.
To adjust belt tension, first remove the belt guard. With the
belt guard removed, loosen motor mount bolts. Loosen the
lock nut and adjust set bolt on the motor tension adjuster
until the required belt tension is achieved. Retighten the
motor mounting bolts.
Shaft
Fig.1
Note: gap between steel
straight edge and sheave
Fig. 2
Never make adjustments to belts or pulleys while engine is running.
DO NOT OVER TENSION as damage to belts and bearings may
occur. Belts that are too loose may slip, resulting in short life and
loss of power to the blade shaft. If any belts are worn or damaged,
replace the complete set.
The motor mounting plate must be maintained parallel to the frame.
Make sure all lock nuts are tightened and retighten the bracket bolts.
NOTE: See parts list for further v-belt specific information.
The two most common causes of misalignment
are shown in the drawings.
Figure 1 - The engine drive shaft and the blade shaft
are not parallel.
Figure 2 - The pulleys are not located properly on the
shafts.
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Revision 03/05/07BFS SERIES
Maintenance
CAUTION
CAUTION
6.10 Electrical System
A fuse protects the battery charging circuit. The fuse and the battery
are the only user serviceable parts of the electrical system. A short
circuit or a battery connected in reverse polarity will blow the fuse.
Refer to the Honda engine manual for the location and type of fuse.
The fuse on the Honda engine is located between the starter solenoid
and the engine, and is rated at 30 amps.
If the fuse blows, determine the cause of the problem before
resuming operation.
6.11 Battery
Check water level weekly. Add distilled water if necessary. Check
terminal cables and remove any deposits. Remove the battery for
recharging and follow the instructions for recharging. Damage can
result to the battery and electrical system if the battery is charged or
installed in reverse polarity. Make sure that the negative terminal is
connected to ground.
Remove and install battery as per instructions in initial servicing
section of this manual. Be careful not to contact metal while
loosening positive terminal with tools.
Observe all battery precautions as outlined in the Initial Servicing
section of this manual.
6.12 Depth Control
The depth control (raising screw) consists of a threaded rod which
feeds into a steel nut. In order to keep the two parts working
smoothly it is necessary to keep the rod free from dirt and sludge as
much as possible. Cleaning the threaded rod with a rag after each
use will prevent sludge from collecting in the tube assembly and
protect the threads. It is a good practice to keep the raising screw
threads lubricated, as the slurry generated during cutting will cause
premature thread wear.
6.13 Water System
Check and clean system periodically. Make sure all outlets in the
blade guard water tubes are open. Clean if necessary. When storing
saw under freezing conditions it is recommended that the water lines
be drained to prevent damage.
Revision 03/05/07 BFS SERIES
27
Troubleshooting
7. Saw Features
When trouble occurs, Be sure to check the simple causes which,
at first, may seem too obvious to be considered. Refer to the table
below for problems and their possible causes.
Problem
Transmission
Jerky when
starting
Transmission
operates in one
Transmission
direction
Transmission
Operating Hot
Oil color is black
Cause
Loose
Transmission
Linkage
Oil Level Cooling
Fan
Water in
Oil
Reservoir
Dirty
Cooling
Fans
X X X
X
X X X X
X X
Loose
Drive
Chain
Engine
Oil color is milky
Cause
Problem
Will Not Start
Hard Starting
Stops
Suddenly
Lacks Power
Operates
Erratically
Knocks or Pings
Skips or
Misfires
Backfires
Overheats
High Fuel Consumption
X
No
Fuel
Improper
Fuel
Dirt in
Fuel
Line
Fuse
Burned
Out
Incorrect
Oil Level
Dirty
Air
Filter
X X X X X
X X X X X
X X X X
X X X X X
X X X X
X X
X X X
X X X
X X X
X X
Faulty
Spark
Plugs
Problem
Other
Reduced Blade Life
Excessive Belt
Wear
Cause
Improper Blade for
the Application
X X
28
Improper Belt
Tension
X X
Damage Caused by
External Objects
Revision 03/05/07BFS SERIES
8. Service Record
Date Service Performed Engine Hours
Service
Revision 03/05/07 BFS SERIES
29
www.wakergroup.com
Wacker Construction Equipment AG · Preußenstraße 41 · D-80809 München · Tel.: +49-(0)89-3 54 02 - 0 · Fax: +49 - (0)89-3 54 02-3 90
Wacker Corporation · P.O. Box 9007 · Menomonee Falls, WI 53052-9007 · Tel. : (262) 255-0500 · Fax: (262) 255-0550 · Tel. : (800) 770-0957
Wacker Asia Pacific Operations · Skyline Tower, Suite 2303, 23/F · 39 Wang Kwong Road, Kowloon Bay, Hong Kong · Tel. +852 2406 60 32 · Fax: +852 2406 60 21
Rev. 02/07
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