Wacker Neuson BTS Series, BTS 930L3, BTS 935L3, BTS 1035L3, BTS 1030L3 Operator's Manual
www.wackergroup.com
0109969en 001
10.2004
Gasoline portable cut-off saw
BTS ...
Operator´s Manual
Important information
This machine has been provided with an EPA-certified engine.
Additional information can be found in the engine
manufacturer‘s notes.
Engine exhaust, some of its constitvents, and certain vehicle
components contain or emit chemicals known to the State of
California to cause cancer and birth defects or other reproduc-
WARNING
tive harm.
Adjusting the engine speed will interfere with EPA certification and
Only authorized personnel can make adjustments to this engine.
Please contact you nearest engine dealer or your Wacker Dealer for more
T00940GB 1
Caution
This engine is an EPA engine.
the emissions.
information.
T00940GB 2
Warranty
for machines equipped with an EPA-certified engine (USA)
EMISSIONS COMPONENT DEFECT WARRANTY COVERAGE
The engine manufacturer warrant(“s”) to the initial retail purchaser and each
subsequent owner, that this non-road engine (herein “engine“) has been designed,
built, and equipped to conform at the time of initial sale to all applicable regulations of
the U.S.Environmental Protection Agency (EPA), and that the engine is free of defects
in materials and workmanship which would cause this engine to fail to conform with
EPA regulations during its warranty period.
For the components listed under PARTS COVERED, the service dealer authorized by
WACKER will, at nocost toyou, make the necessary diagnosis, repair, or replacement
necessary to ensure that the engine complies with applicable U.S. EPA regulations.
EMISSISON COMPONENT DEFECT WARRANTY PERIOD
The warranty period for this engine begins on the date of sale to the initial purchaser
and continues for a period of 2 years.
PARTS COVERED
Listed below are the parts covered by the Emission Components Defect Warranty.
Some ofthe parts listed below mayrequire scheduled maintenance and arewarranted
up to the first scheduled replacement point for that part.
Fuel Metering System
Carburetor and internal parts
Fuel filter, if applicable
Throttle stopper, if applicable
Choke System, if applicable
Air Induction System
Air cleaner plate, Air filter
Air cleaner case, Intake manifold
Ignition System
Spark plugs
Flywheel Magneto
Ignition Coil
Miscellaneous Items Used in Above Systems
Fuel hoses, clamps and sealing gaskets
OBTAINING WARRANTY SERVICE
To obtain warranty service, take your engine to the nearest authorized WACKER
service dealer. Bring your sales receipts indicating date of purchase for this engine.
The service dealer authorized by WACKER will perform the necessary repairs or
adjustments within a reasonable amount of time and furnish you with a copy of the
repair order. All parts and accessories replaced under this warranty become the
property of WACKER.
T00965GB 3
WHAT IS NOT COVERED?
∗ Conditions resulting from tampering, misuse, improper adjustment
(unless theywere madeby the service dealer authorized by WACKER
during a warranty repair), alteration, accident, failure to use the
recommended fuel and oil, or not performing required maintenance
services.
∗ The replacement parts used for required maintenance services.
∗ Consequential damages such as loss of time, inconvenience, loss of
use of the engine or equipment, etc.
∗ Diagnosis and inspectionchargesthat do notresult in warranty-eligible
service being performed.
∗ Any non-authorized replacement part, or malfunction of authorized
parts due to use of non-authorized parts.
OWNER’S WARRANTY RESPONSIBILITIES
As the engine owner, you are responsible for the performance of the required
maintenance listed in your owner’s manual. WACKER recommends that you retain all
receipts covering maintenance on your engine, but WACKER cannot deny warranty
solely for the lack of receipts or for your failure to ensure the performance of all
scheduled maintenance. As the engine owner, you should however be aware that
WACKER may denywarranty coverage ifyour engine ora part hasfailed due toabuse,
neglect, improper maintenance or unapproved modifications.
You are responsible for presenting your engine to the nearest service dealer
authorized by WACKER when a problem exists.
If you have any questions regarding your warranty rights and responsibilities, you
should contact the WACKER CORPORATION Product Support Department (U.S.A. 1800-770-0957, Canada 1-877-977-0775) for the information.
THINGS YOU SHOULD KNOW ABOUT THE EMISSION CONTROL SYSTEM
WARRANTY:
T00965GB 4
MAINTENANCE AND REPAIRS
You are responsible for the proper maintenance of the engine. You should keep all
receipts and maintenance records covering the performance of regular maintenance in
the event questions arise. These receipts and maintenance records should be
transferred to each subsequent owner of the engine. WACKER reserves the right to
deny warranty coverage if the engine has not been properly maintained. Warranty
claims willnot be denied, however, solely because ofthe lack of required maintenance
or failure to keep maintenance records.
MAINTENANCE, REPLACEMENT OR REPAIR OF EMISSION CONTROL DEVICES
AND SYSTEMS MAY BE PERFORMED BY ANY REPAIR ESTABLISHMENT OR
INDIVIDUAL; HOWEVER, WARRANTY REPAIRS MUST BE PERFORMED BY A
SERVICE DEALER AUTHORIZED BY WACKER. THE USE OF PARTS THAT ARE
NOT EQUIVALENT IN PERFORMANCE AND DURABILITY TO AUTHORIZED
PARTS MAY IMPAIR THE EFFECTIVENESS OF THE EMISSION CONTROL
SYSTEM AND MAY HAVE A BEARING ON THE OUTCOME OF A WARRANTY
CLAIM.
If other than the parts authorized byWACKER areused formaintenance replacements
or for the repair of components affecting emission control, you should assure yourself
that such parts are warranted by their manufacturer to be equivalent to the parts
authorized by WACKER in their performance and durability.
HOW TO MAKE A CLAIM
All repair qualifying under this limited warranty must be performed by a service dealer
authorized by WACKER. In the event that any emission-related part is found to be
defective during the warranty period, you shall notify WACKER CORPORATION
Product Support Department (U.S.A. 1-800-770-0957, Canada 1-877-977-0775) and
you will be advised of the appropriate warranty service dealer or service providers
where the warranty repair can be performed.
T00965GB 5
T00965GB 6
Operating instructions
1. Foreword
For your own safety and protection from bodily injuries, carefully read,
understand and follow the safety instructions in this manual.
Please operate and maintain your Wacker machine in accordance with
the instructions in this manual. Your Wacker machine will reward your
attention by giving trouble-free operation and a high degree of
availability.
Defective machine parts are to be replaced as soon as possible.
All rights, especially the right for copying and distribution are reserved
Copyright by Wacker Construction Equipment AG
No part of this publication may be reproduced in any form or by any
means, electronic or mechanical, including photocopying, without
express permission in writing from Wacker Construction Equipment AG.
Any type of reproduction, distribution or saving on data carriers of any
type or method not authorized by Wacker represents an infringement of
valid copyrights and will be prosecuted. We expressly reserve the right
to technical modifications - even without express due notice - which aim
at improving our machines or their safety standards.
7
Table Of Contents
1. Foreword 7
2. Thank you for purchasing a WACKER product! 10
2.1 Packing ............................................................................................... 11
3. Delivery Inventory/Symbols 12
3.1 Delivery Inventory ............................................................................... 12
3.2 Symbols .............................................................................................. 12
4. Safety precautions 14
4.1 Use as designed ................................................................................. 14
4.2 General precautions ........................................................................... 14
4.3 Personal protective equipment ........................................................... 15
4.4 Fuels/Refuelling .................................................................................. 17
4.5 Putting into operation ......................................................................... 18
4.6 Cutting blades .................................................................................... 19
4.7 Kickback and lock-in ........................................................................... 22
4.8 Working behavior/Method of working ................................................. 23
4.9 Cutting metals .................................................................................... 24
4.10 Cutting masonry concrete, asbestos or asphalt ................................. 27
4.11 Transport and storage ........................................................................ 29
4.12 Maintenance ....................................................................................... 30
4.13 First aid ............................................................................................... 31
5. Technical data 32
6. Denomination of components 34
7. Putting into operation 36
7.1 Fitting cutting blades .......................................................................... 37
7.2 Tightening the V-belt/Checking V-belt tension ................................... 38
7.3 Fuels ................................................................................................... 39
7.4 Fuel storage ....................................................................................... 40
7.5 Refuelling ........................................................................................... 41
7.6 Starting the engine .............................................................................42
8
Table Of Contents
7.7 Cold-starting ....................................................................................... 43
7.8 Warm-starting ..................................................................................... 44
7.9 Stopping the engine ........................................................................... 44
7.10 Adjusting the carburetor ..................................................................... 44
8. Maintenance 46
8.1 Changing the V-belt ............................................................................ 47
8.2 Cleaning the protective hood .............................................................. 48
8.3 Cleaning/changing the air filter ........................................................... 48
8.4 Prefilter and air cleaner insert ............................................................ 50
8.5 Replacing the spark plug .................................................................... 51
8.6 Checking the ignition spark ................................................................ 52
8.7 Replacing the suction head ................................................................ 53
8.8 Starter rope replacement .................................................................... 53
8.9 Replace the return spring ................................................................... 55
8.10 Cutting arm in inboard/outboard ......................................................... 56
8.11 Repositioning the cutting arm ............................................................. 57
8.12 Instructions for periodic maintenance ................................................. 59
8.13 Troubleshooting .................................................................................. 61
9. FBTS 62
9.1 Guide cart ........................................................................................... 62
9.2 Safety precautions .............................................................................. 63
10. Labels 64
EC - Confornity Certificate 65
DIN EN ISO 9001 CERTIFICATE 67
9
Thank you for purchasing a WACKER product!
2. Thank you for purchasing a WACKER product!
Congratulations on choosing a WACKER Power Cut cutoff saw!
WACKER Portable Cut-off Saws feature specially designed highperformance engines with outstanding power-to-weight ratios, for
heavy-duty yet lightweight tools.
Other advantages of the WACKER Portable Cut-off Saws:
∗ Sturdy construction and high reliability.
∗ Maintenance-free electronic ignition, hermetically sealed to protect
against dust and moisture.
∗ Vibration damping with 2-mass system for Less fatigue-oróne working
even when guiding the Cut-off Saw by hand.
∗ Five-stage air-filter system for reliable working even under very dusty
conditions.
∗ Two options for mounting the cutting arm: Either inboard, for good
balance when guiding the unit manually, outboard, for flush cuts along
walls or curbsides or horizontally directly above the ground.
∗ Extensive range of accessories available, such as resinoid-bonded or
diamond-tipped cutting blades as well as a guide trolley, water
sprinkling system or angled fuel tank filler neck.
We want you to be satisfied with your WACKER product.
In order to guarantee the optimal function and performance of your
Cut-off Saw and to ensure your personal safety we would request you
to perform the following:
Read this instruction manual carefully before putting the Cut-off
Saw into operation for the first time, and strictly observe the
safety regulations! Failure to observe these precautions can lead
to severe injury or death
T00961GB 10
2.1 Packing
Your WACKER Power Cut is packed in a cardboard box to prevent
shipping damage.
Cardboard is a basic raw material and is consequently reuseable or
suitable for recycling (waste paper recycling).
Thank you for purchasing a WACKER product!
T00961GB 11
Delivery Inventory/Symbols
3. Delivery Inventory/Symbols
3.1 Delivery Inventory
In case one of the parts listed should not be included in the delivery
inventory, please consult your sales agent!
3.2 Symbols
You will notice the following symbols on the saw and in the operator´s
manual:
1. Cut-off saw
3. Universal wrench 13/19
4. Allen key
5. Screwdriver for carburetor adjusment
6. Operator‘s manual (not shown)
Read operator´s manual and
follow the warning and
safety precautions!
CombinationswitchStart/Stop
(I/O), choke
T00961GB 12
Delivery Inventory/Symbols
Particular care and caution! Locked / Unlocked
Forbidden! Use eye protection!
Wear protective helmet, eye
and ear protection!
Wear protective gloves! Stop engine!
Wear respiratory protection! Warning! Kickback!
No smoking! Fuel/oil mixture
No open fire! First aid
Turning direction of cutting
blade
Engine - manual start
Recycling
Max. peripheral blade speed CE - marking
Cutting blade dimensions
T00961GB 13
Safety precautions
4. Safety precautions
4.1 Use as designed
Cut-off saw
The cut-off saw may only be used for the cutting/shortening of
appropriate materials outdoors with a cutting blade approved for the
machine
Unauthorized working procedure
The cutting blades of the cut-off saw may not be used for grinding
purposes (removal of material with the side face of the cutting blade).
This could cause the blade to fracture! Fitting the cut-off saw with
circular saw discs, knives, brushes etc. is absolutely forbidden.
Non-authorized operators:
Persons who are not familiar with the operator´s manual, children,
teenagers, as well as persons under the influence of alcohol, drugs or
medication are not allowed to operate the machine.
4.2 General precautions
4.2.1 The operator MUST read this manual to ensure safe operation
(even if you already have experience in using cut-off saws), It is
important tobe familiar with the operationof this particular cut-off saw.
Users insufficiently informed will endanger themselves as well as
others due to improper handling.
1
4.2.2 Let only persons who have experience in using cut-off saws work with
this unit. When letting another person use the cut-off saw, this manual
must be provided along with it.
4.2.3 First-time operators should ask a specialist to instruct them in working
with gasoline-powered cut-off saws.
4.2.4 Children and persons under 18 years of age must not be allowed to
use this cut-off saw. Persons over the age of 16 years may, however,
use the cut-off saw for the purpose ofbeing trainedas longas theyare
under the supervision of a qualified trainer.
4.2.5 Working with the cut-off sawrequires high concentration.
4.2.6 Operate the PowerCut only ifyou are ingood physicalcondition. If you
are tired, your attention will be reduced. Be especially careful at the
end of a working day. Perform all work calmly and carefully. The user
has to accept liability for others.
SV00068GB 14
4.2.7 Never work while under the influence of alcohol, drugs, medication or
other substances which may impair vision, dexterity or judgement.
2
4.2.8 Ar fire extinguisher must be available in the immediate vicinity when
working in easily inflammable vegetation or when it has not rained for
a long time (danger of fire).
4.2.9 Asbestos and other materials that can release toxins may be cut only
with the necessary safety precautions and after notification of the
proper authorities and under their supervision or that of a person
appointed by them.
4.3 Personal protective equipment
4.3.1 In order to avoid head, eye, hand or foot injuries as well as to
protect your hearing the following protective equipment must be
used during operation of the cut-off saw:
Safety precautions
4.3.2 The kindof clothing should be appropriate, i. e. itshould be tight-fitting
but not be a hindrance. Clothing in which grains of material can
accumulate (trousers with cuffs, jackets and trousers with wide-open
pockets, etc.) must not be worn, particularly when cutting metal.
4.3.3 Do not wear any jewellery or clothing that can get caught or distract
from the operation of the cut-off saw.
3
4.3.4 It is necessary to wear a protective helmet whenever working with the
cut-off saw. The protective helmet (A) is to be checked in regular
intervals for damage and is to be replaced after 5 years at the latest.
Use only approved protective helmets.
4.3.5 The helmet visor (B) protects the face from dust and material grains.
In order to prevent injuries to eyes and face, always wear protective
goggles (C) or visor when using the cut-off saw.
SV00068GB 15
Safety precautions
4.3.6 To prevent hearing damage, always wear suitable personal hearing
protection. (ear muffs (D), ear plugs, etc.). Octave brand analysis
upon request.
4
4.3.7 When dry-cutting dust-producing materials such as stone or concrete,
always wear approved respiratory protection (E).
4.3.8 Work gloves (F) of tough leather are part of the required work kit of
the cut-off saw and must always be worn when working with the cut-off
saw.
5
4.3.9 Always wear safety shoes or boots (G) with steel toes, non-skid
soles, and leg protectors when working with the cut-off saw. Safety
shoes equipped with a protective layer provide protection against cuts
and ensure a secure footing.
4.3.10 Always wear a work suit (H) of sturdy material.
SV00068GB 16
4.4 Fuels/Refuelling
4.4.1 Go to a safe, level place before refuelling. Never refuel while on
scaffolding, on heaps of material, or in similar places!
4.4.2 Switch off the engine before refuelling the Power Cut.
6
4.4.3 Do not smoke or work near open fires (6).
4.4.4 Let the engine cool down before refuelling.
4.4.5 Fuelscan contain substancessimilarto solvents. Eyesandskin should
not come in contact with mineral oil products. Always wear protective
gloves when refuelling (notthe regularwork gloves!).Frequently clean
and change protective clothes. Do not breathe in fuel vapors.
Inhalation of fuel vapours can be hazardous to your health.
4.4.6 Do not spill fuel. If a spill occurs, clean off the cutt-off sawimmediately.
Fuel should not come in contact with clothes. If your clothes have
come in contact with fuel, change them at once.
Safety precautions
4.4.7 Ensure that no fuel runs into the soil (environmental protection). Use
an appropriate base.
4.4.8 Refuelling is notallowed in closedspaces. Fuel vaporswill accumulate
near the floor (explosion hazard).
4.4.9 Make sure to firmly tighten the screw plug of the fuel tank.
3 meters
(10 feet)
7
4.4.10 Before starting the engine, move to a location at least 3 meters (10
feet) from where you fuelled the cut-off saw (7), but not within the
extended swing range of the cutting blades (direction of sparks).
4.4.11 Fuel cannot bestoredfor an unlimitedperiodof time. Buyonly as much
as will be consumed in the near future.
4.4.12 When making up the gasoline/oil mixture, always put the oil in the
mixing container
SV00068GB 17
first, and then the gasoline.
Safety precautions
4.4.13 Use only approved and marked containers for the transport and
storage of fuel.
Keep fuel away from children!
4.5 Putting into operation
4.5.1 Do not workon your own. There must be someone aroundin case
of an emergency (within shouting distance).
4.5.2 Observe all anti-noise regulations when working in residential areas.
4.5.3 Never use the PowerCut near inflammable materials or explosive
gases! The Power Cut can create sparks leading to fire or
explosion!
30 m(100 feet)
= Wear protective equipment
8
4.5.4 Make sure that all persons within 30 meters (100 feet), such as other
workers, arewearing protective gear (see „Protective Equipment“) (8).
Children and other unauthorized persons must remain more than 30
meters (100 feet) away from the working area. Keep an eye out for
animals as well (9).
9
4.5.5 Before starting work the cut-off saw must be checked for perfect
function and operating safety in aaccordance with regulations.
SV00068GB 18
In particular, make sure that the cutting blade is in good conditions
(replace immediately if torn, damaged or bent), the cutting blade is
properlymounted, the protectivehood is lockedinplace, the V-belthas
the proper tension, the throttle moves easily and the half-throttle lock
button functions properly, the handles are clean and dry, and the
combination switch functions properly.
4.5.6 Start the cut-off saw only after complete assembly and inspection.
Never use the cutt-off saw when it is not completely assembled.
4.6 Cutting blades
4.6.1 The protective hood must always be on! Change cutting blades
only with the engine off!
Always make sure to observe the „direction of rotation“ markings.
When using diamond cutting blades.
Safety precautions
10
4.6.2 Cutting blades have been designed exclusively for radial loads. Never
use theside face of the cuttingblade for grinding purposes, asthere is
danger of blade fracture.
min. 5 m
(16 feet)
11
ATTENTION!
Never change direction (turning radius less than 5 meters (16
feet), exert lateral (sideways) pressure, or cant the cut-off saw
during cutting applications (11)!
4.6.3 Use a cutting blade only for cutting the materials it is intended for. The
proper type of blade must be selected for either metals or concrete.
SV00068GB 19
Safety precautions
4.6.4 The arbour hole (bore) of the cutting blade must fit the shaft exactly. If
the arbour hole islarger thanthe shaftdiameter, aspacer ringmust be
used.
4.6.5 Free-hand cutting blades with a blade diameter of 355 mm (14“) must
be approved for speeds of up to 4370 1/min (rpm) or80 m/s (260 ft./
sec); blades with a blade diameter of 300 mm (12“) must be approved
for speeds of up 5100 1/min (rpm) or 80 m/s (260 ft./sec).
12
4.6.6 The cutting blade must be free of defects (12). Make sure by sound
testing with a piece of wood. Do not use defective cutting discs.
Always tighten the cutting blade‘s mounting bolt to a torqueof 30
Nm (22.2ft.lbs.). Otherwise, the cutting blade could warp.
4.6.7 Make sure you have a steady footing before starting the cutting blade.
13
4.6.8 Put the cut-offsawinto operationonlyas described inthis manual (13).
Always place your left foot in the rear handle and grasp the other
handle firmly (with thumb and fingers). Other starting methods are not
allowed.
4.6.9 When starting the cut-off saw it must be well supported and securely
held. The cutting blade must not be touching anything.
4.6.10 If the cutting blade is new, test it by running it at least 60 seconds at
top speed. When doing this, make sure that no persons or body parts
are in the extended swing range of the cutting blade, in case it is
defective and flies apart.
SV00068GB 20
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