Wacker Neuson BTS 930, BTS 1035, BTS 935, FBTS, BTS 1030 Operator's Manual
www.wackergroup.com
Operator´s Manual
POWER CUT
BTS 930
BTS 935
BTS 1030
BTS 1035
FBTS
0200367en - 10.2002
0008340 103
0008341 103
0008339 102
0007975 102
0125766
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FOREWORD
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 maybe reproduced in any form or by anymeans, electronic or mechanical, including
photocopying, without express permission in writing from Wacker Construction Equipment AG.
Any typeofreproduction,distributionorsavingondata 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.
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TABLE OF CONTENTS
FOREWORD 1
Packing 4
DELIVERY INVENTORY 5
Symbols 5
SAFETY PRECAUTIONS 7
General precautions 7
Personal protective 7
Fuels / Refuelling 8
Putting into operation 10
Cutoff discs 10
Kickback and lock-in 12
Working behavior / Method of working 13
Cutting metals 13
Transport and storage 16
Maintenance 16
First aid 17
TECHNICAL DATA BTS 930 / 935 19
TECHNICAL DATA BTS 1030 / 1035 20
DENOMINATION OF COMPONENTS 21
PUTTING INTO OPERATION 22
Mounting the cutting disc 22
Tightening the V-belt / Checking V-belt tension 23
Fuels 24
Refuelling 26
Starting the engine 26
Cold-starting 28
Warm-starting 28
Stopping the engine 29
Working in winter 29
Adjusting the carburetor 31
MAINTENANCE 33
Changing the V-belt 33
Cleaning the protection hood 35
Cleaning / changing the air filter 35
Foam prefilter and inner filter 37
Replacing the spark plug 37
Checking the ignition spark 39
Replacing the suction head 39
Replacing the starter cable 39
Replacing the return spring 41
Cutting attachment in central / side position 43
Repositioning the cutting attachment 43
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TABLE OF CONTENTS
SPECIAL ACCESSORIES 45
Instructions for periodic maintenance 46
Service, spare parts and guarantee 47
Troubleshooting 48
LABELS 49
FBTS 51
Guide trolley: 51
Safety precautions 51
CUTTING DISCS 52
CUTTING DISCS 54
EC - CONFORMITY-CERTIFICATE 55
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Thank you for purchasing a WACKER product!
Congratulations on choosing a WACKER Power Cut cutoff saw! The WACKER Power Cuts feature specially
designed high-performance engines with outstanding power-to-weight ratios, for heavy-duty yet lightweight
tools.
Other advantages of the WACKER Power Cuts:
*Sturdy construction and high reliability.
*Maintenance-free electronic ignition, hermetically sealed to protect against dust and moisture.
*Vibration damping with 2-mass system for tireless working even when guiding the Power Cut by hand.
*Five-stage air-filter system for reliable working even under very dusty conditions.
*Two options for mounting the cutter attachment: Either centrally, for good balancewhen guiding the unit man-
ually, or on the side, 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 discs as wellas
a guide trolley, water sprinkling system or angled tank filler neck.
We want you to be satisfied with your WACKER product.
In order to guarantee the optimal function and performance of your Power Cut and to ensure your personal
safety we would request you to perform the following:
Read this instruction manual carefully before putting the Power Cut into operation for the first time,
and strictly observe the safety regulations! Failure to observe these precautions can lead to severe injury or death!
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).
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DELIVERY INVENTORY
1. Power Cut
3. Universal wrench 13/19
4. Offset screwdriver
5. Screwdriver for carburetor adjusment In case one of the parts listed should not be included in
6. Instruction manual (not shown) the delivery inventory, please consult your sales agent.
Symbols
You will notice the following symbols on the saw and in the Instruction Manual:
Read instruction manual and follow
the warning- and safety precautions!
Combination Start/Stop (I/O) switch,
choke
Particular care and caution! Locked / Unlocked
Forbidden! Press starting valve
Wear protective helmet, eye and ear
protection!
Engine - manual start
Wear protective gloves! Working in winter
Wear respiratory protection! Stop engine!
No smoking! Warning! Kickback!
No open fire!
Fuel and oil mixture
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Direction of cutting wheel rotation
First aid
Warning: the max. peripheral speed
of the cutting disc is 80 m/s!
Recycling
Cutting disc dimensions
CE - Marking
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SAFETY PRECAUTIONS
General precautions
- The operator MUST read this instruction manual to
ensure safe operation (even if you already have
experience in using cutoff saws). It is important to
be familiar with the operation of this particular cutoff
saw. Users insufficiently informed will endanger
themselves as well as others due to improper
handling.
- Let only persons who have experience in using cutoff
saws work with this unit. When letting another person
use the Power Cut, this instruction manual must be
provided along with it.
- First-time operators should ask a specialist to instruct
them in working with gasoline-powered cutoff saws.
- Children and persons under 18 years of age must not
be allowed to use this Power Cut. Persons over the
age of 16 years may, however, use the Power Cut for
the purpose of being trained as long as theyare under
the supervision of a qualified trainer.
- Working with the Power Cut requires high
concentration.
- Operate the Power Cut only if you are in good physical
condition. If you are tired, your attention will be
reduced. Be especially careful at the end of a working
day. Perform all work calmly and carefully. The user
has to accept liability for others.
- Never work while under the influence of alcohol,
drugs, medication or other substances which may
impair vision, dexterity or judgement.
- Ar fire extinguisher must be availablein theimmediate
vicinity when working in easily inflammable vegetation
or when it has not rained for a long time (danger of
fire).
- Asbestos and other materials that can release toxins
may be cut only with the necessary safety precautions
and after notification of the proper authorities and
under their supervision or that of a person appointed
by them.
Personal protective
- 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 Power Cut:
- The kind of clothing should be appropriate, i. e. it
should be tight-fitting but not be a hindrance. Clothing
in which grains of material can accumulate (trousers
with cuffs, jackets and trousers with wide-open
pockets, etc.) must not be worn, particularly when
cutting metal.
- Do not wear any jewellery or clothing that can get
caught or distract from the operation ofthe PowerCut.
- It is necessary to wear a protective helmet whenever
working with the Power Cut. 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.
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- 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 Power Cut.
- To prevent hearing damage, always wear suitable
personal hearing protection. (ear muffs (D), ear
plugs, etc.). Octave brand analysis upon request.
- When dry-cutting dust-producing materials such as
stone or concrete, always wear approved respiratory
protection (E).
- Work gloves (F) of tough leather are part of the
required work kit of the Power Cut and must always be
worn when working with the Power Cut.
- Always wear safety shoes or boots (G) with steel
toes, non-skid soles, and leg protectors when working
with the Power Cut. Safety shoes equipped with a
protective layer provide protection against cuts and
ensure a secure footing.
- Always wear a work suit (H) of sturdy material.
Fuels / Refuelling
- Go to a safe, level place before refuelling. Never
refuel while on scaffolding, on heaps of material,
or in similar places!
- Switch off the engine before refuelling the Power Cut.
- Do not smoke or work near open fires (6).
- Let the engine cool down before refuelling.
- Fuelscan contain substances similar to solvents.Eyes
and skin should not come in contact with mineral oil
products. Always wear protective gloves when
refuelling (not the regular work gloves!). Frequently
clean andchange protective clothes. Do not breathe in
fuel vapors. Inhalation of fuel vapours can be
hazardous to your health.
- Do not spill fuel. If a spill occurs, clean off the Power
Cut immediately. Fuel should not come in contact with
clothes. If your clothes have come in contact with fuel,
change them at once.
- Ensure that no fuel oozes into the soil (environmental
protection). Use an appropriate base.
- Refuelling is not allowed in closed rooms. Fuel vapors
will accumulate near the floor (explosion hazard).
- Ensure to firmly tighten thescrew plugof thefuel tank.
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- Before starting the engine, move to a location at least
3 meters (approx. 3 1/4 yards) from where you fuelled
the Power Cut (7), but not within the extended swing
range of the cutting disc (direction of sparks).
- Fuel cannot be stored for an unlimited period of time.
Buy only as much as will be consumed in the near
future.
- When making up the gasoline/oil mixture, always put
the oil in the mixing container first, and then the
gasoline.
- Use only approved and marked containers for the
transport and storage of fuel.
- Keep fuel away from children!
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3 meters
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Putting into operation
- Do not work on your own.There must be someone
around in case of an emergency (within shouting
distance).
- Observe all anti-noise regulations when working in
residential areas.
- Never use the Power Cut near inflammable
materials or explosive gases! The Power Cut can
create sparks leading to fire or explosion!
- Make sure that all persons within 30 meters (33
yards), such as other workers, are wearing protective
gear (see „Protective Equipment“) (8). Children and
other unauthorizedpersons must remain more than 30
meters away from the working area. Keep an eye out
for animals as well (9).
- Before starting work the Power Cut must be
checked for perfect function and operating safety
according to the prescriptions.
In particular, make sure that the cutting wheel is in
good condition (replace immediately if torn, damaged
or bent), the cutting wheel is properly mounted, the
protective hood is locked in place, the hand guard is
properly mounted, the V-belt has the proper tension,
the throttle moves easily and the half-throttle lock
button functions properly, the grips are clean and dry,
and the combination switch functions properly.
- Start the Power Cut only after complete assembly and
inspection. Never use the Power Cut when it is not
completely assembled.
Cutoff discs
- The protection hood must always be on! Change
discs only with the engine off!
- There are two basic types of cutoff discs:
- For metal (hot cutting)
- For masonry (cold cutting)
NOTE: When using diamond cutoff discs, always
make sure to observe the „direction of rotation“
markings. Diamond discs should not be used for
cutting metal.
- Cutoff discs are intended only for radial loading, i.e. for
cutting. Do not grind with the sides of the cutting disc!
This will break the disc (10)!
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=waring Protective
Equipment
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Caution!
Never change direction (turning radius less than 5
meters / 5 1/2 yards), exert lateral (sideways)
pressure, or tip the Power Cut during cutting (11)!
- Use a cutting disc only for cutting the materials it is
intended for. The proper type of disc must be used, for
either metals or concrete.
- The arbour hole (bore) of the cutting disc must fit the
shaft exactly. If the arbour hole is larger than the shaft
diameter, a spacer ring must be used (accessories).
- Use only cutting wheels approved by the DSA
(German Abrasive Disc Committee) or equivalent
organisation for freehand cutting at up to 4370 RPM (=
80 m/sec. at circumference) for 14“/355 mm discs, or
up to 5100 RPM (= 80 m/sec. at circumference) for
12“/300 mm discs.
- The disc 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 disc mounting bolt to a
torque of 30 Nm. Otherwise, the cutting disc can
twist.
- Before starting the cutting disc, make sure you have a
steady footing.
- Put the Power Cut into operation only as described in
this instruction 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.
- When starting the Power Cut it must be well supported
and securely held. The cutting disc must not be
touching anything.
- If the cutting disc isnew, testit byrunning itat least60
seconds at top speed. When doing this, make sure
that no persons or body parts are in the extended
swing range of the disc, in case itis defective and flies
apart.
- When working with the Power Cut always hold it
with both hands. Take the back handle with the right
hand and the tubular handle with the left hand. Hold
the handles tightly with your thumbs facing your
fingers.
- CAUTION: When you release the throttle lever the
disc will keep spinning for a short period of time
(free-wheeling effect.).
- Continuously ensure that you have a safe footing.
- Hold the Power Cut such that you will not breathe in
the exhaust gas. Do not work in closed rooms or in
deep holes or ditches (danger of poisoning by fumes).
- Switch off the Power Cut immediately if you
observe any changes in its operating behavior.
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min. 5 m
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- Switch off the engine before inspecting the V-belt
tension or tightening it, replacing the cutting
wheel, repositioning the cutter attachment (side or
middle position) or eliminating faults (14).
- Turn off the engine immediately and check the disc if
you hear or feel any change in cutting behaviour.
- Turn off the Power Cut when taking a break or
stopping work (14). Place the unit in such a way that
the disc is not touching anything and cannot endanger
anyone.
- Do not put the overheated Power Cut in dry grass or
on any inflammable objects. The muffler is very hot
(danger of fire).
- IMPORTANT: After wet cutting, first turn off the water
feed and then let the disc run at least 30 seconds, to
fling off the remaining water and prevent corrosion.
Kickback and lock-in
- When working with the Power Cut there is a danger of
kickback and lock-in.
- Kickback occurs when the top of the cutting disc is
used for cutting (15).
- This causes the Power Cut to be thrown back toward
the user with great force and out of control. Risk of
injury!
To prevent kickback, observe the following:
- Never cut with the section of the cutting disc shown in
figure 15.
Be especially careful when reinserting the disc
into cuts that have already been started!
- Lock-in occurs when the cut narrows (crack, or
workpiece under stress).
- This causes the Power Cut to suddenly jump forward,
out of control and with great force. Risk of injury!
To prevent lock-in, observe the following:
- When reinserting the disc into previous cuts, have the
Power Cut running at top speed. Always cut at top
speed.
- Always support the workpiece so that the cut is under
tension (16), so that the cut does not press together
and jam the cutting disc as it proceeds through the
material.
- When starting a cut, apply the disc to the workpiece
with care. Do not just shove it into the material.
- Never cut more than one piece at a time! When
cutting, make sure that no other workpiece comes into
contact.
*
Maintenance
*
Refuelling
*
Changing cutoff
discs
*
Repositioning the
cutting attachment
*
Stopping work
*
Transport
*
Putting out of
function
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Working behavior / Method of working
- Before starting work, check the work area for any
hazards (electrical wires, inflammable substances).
Clearly mark the work area (for example with warning
signs or by cordoning off the area).
- When working with the Power Cut hold it firmly by the
front and rear handles. Never leave the Power Cut
unattended!
- Whenever possible run the Power Cut at the rated
arbour speed (see „Technical Data“).
- Only use the Power Cut during good light and visibility
periods. Be aware of slippery or wet areas, and of ice
and snow (risk of slipping).
- Never work on unstable surfaces. Make sure that
there are no obstacles in the working area, risk of
stumbling. Always ensure that you have a safe footing.
- Never cut above your shoulder height (17).
- Never stand on a ladder to cut (17).
- Never use the Power Cut while standing on
scaffolding.
- Do not lean over too far when working. When putting
down and picking up the Power Cut, do not bend over
from the waist, but instead bend in the knees. Save
your back!
- Guide the Power Cut in such a way that no part of your
body is within the extended swing range of the disc
(18).
- Use cutting discs only for the materials for which they
are designed!
- Use cutting discs only for the materials for which they
are designed. Do not use the Power Cut to lift up and
shovel away pieces of material and other objects.
Important! Before cutting, remove all foreign objects,
such as rocks, gravel, nails etc. from the cutting area.
Otherwise, such objects can beflung away by the disc
with great speed. Injury hazard!
- When cutting workpieces down to length use a firm
support. If necessary, secure the workpiece from
slipping, but do not steady it with your foot or allow
another person to hold it.
- When cutting round items, always secure them
against rotation.
- When guiding the Power Cut by hand, use the side
mounting position of the cutter attachment only when
actually necessary. Otherwise, always use the central
position. This gives the unit a better balance, for
reduced operator fatigue.
Cutting metals
IMPORTANT!
Always wear approved respiratory protection!
Materials that can release toxic substances may
be cut only after notifying the proper authorities
and under their supervision or that of a person
appointed by them.
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CAUTION!
The rapid rotation of the cutting disc heats metal
and melts it at the point of contact. Swing the
guard as far down as possible behind the cut (19)
in order to direct the stream of sparks forward,
away from the operator (fire hazard).
- Determine the direction of cutting, mark the cut and
apply the disc to the material at moderate speed,to cut
a guide groove before going to top speed and applying
more pressure to the Power Cut.
- Keep the disc straight and vertical. Do not tip it, as this
can break it.
- The best way to get a good, clean cut is to pull or move
the Power Cut back and forth. Do not simply press the
disc into the material.
- Thick round stock is best cut in stages (20).
- Thin tubing and pipes can be cut with a simple
downward cut.
- Cut large-diameter pipes as for round stock. To
prevent tipping and for better control, do not letthe disc
sink too deeply into the material. Instead, always cut
shallow around the whole piece.
- Worn discs have a smaller diameter than new discs, so
that at the same engine speed they have a lower
effective circumferential speed and therefore do not
cut as well.
- Cut I-beams and L-bars in steps; see Figure 21.
- Cut bands and plates like pipes: along the wide side
with a long cut.
- When cutting material under stress (supported
material or material in structures), always make a
notch in the thrust (pressure) side, and then cut from
the tension side, so that the disc does not lock in (22).
Secure cutoff material from falling!
CAUTION!
If there is a chance that the material is under
stress, be prepared for it to kick back. Make sure
you can get out of the way if you have to!
Be particularly careful in scrap-metal yards,
junkyards, at accident sites, and with haphazard
piles of material. Precariously balanced pieces or
pieces under stress can act in unpredictable ways,
and may slide, jump out, or burst. Secure cutoff
material from falling (22)! Always exercise extreme
caution and use only equipment that is in perfect
working order.
Observe the accident-prevention rules and
regulations of your employer and/or insurance
organization.
Cutting masonry concrete, asbestos or asphalt.
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IMPORTANT!
Always wear approved respiratory protection!
Asbestos and other materials that can release
toxic substances may be cut only after notifying
the proper authorities and under their supervision
or that of a person appointed by them. When
cutting prestressed and reinforced concrete piles,
follow the instructions and standards of the
responsible authorities or the builder of the
structural member. Reinforcement rods must be
cut in the prescribed sequence and in accordance
with applicable safety regulations.
NOTE!
Mortar,stone, and concrete develop large quantitiesof
dust during cutting. To increase the lifetime of the
cutting disc (by cooling), to improve visibility, and to
avoid excessive dust creation, we strongly
recommend wet cutting instead of dry cutting.
In wet cutting, the disc is wetted at an equal rate on
both sides by a trickle of water. WACKER offers the
right accessories for all wet cutting applications (see
also “SPECIAL ACCESSORIES“).
- Remove foreign objects such as sand, stones and
nails found within the working area. Caution: Watch
out for electric wires and cables!
The rapid rotation of the cutting disc at the point of
contact throws fragments out of the cut groove at
high speed. For your safety, swing the protection
hood down as far as possible behind the cut (23),
so that material fragments are thrown forward,
away from the operator.
- Mark the cut, and then make a groove about 5 mm
(just under 1/5“) along the entire length of the planned
cut. This groove will then guide the Power Cut
accurately guring the actual cutoff.
NOTE:
For long, straight cuts we recommend using a trolley
(24, see also “SPECIAL ACCESSORIES“). This
makes it much easier to guide the unit straight.
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- When cutting slabs to size, you need not cut through
the entire material thickness (creating unnecessary
dust). Instead, simply make a shallow groove, and
then knock off the excess material cleanly on a flat
surface (25).
CAREFUL!
When cutting into lengths, cutting through material,
making cutouts, etc., always make sure to plan the
direction and sequence of cuts in such a way that the
disc does not get jammed by the cut-off piece, and that
no persons can be injured by falling pieces.
Transport and storage
- Always turn off the Power Cut when transporting it
or moving it from place to place on a site (26).
- Never carry or move the unit with the engine on or
the disc moving!
- Carry the unit only by the tubular (middle) handle with
the cutting disc pointing behind you (26). Avoid
touching the exhaust muffler (burn hazard!).
- When moving the Power Cut over longer distances,
use a wheelbarrow or wagon.
- When transporting the Power Cut in a vehicle, make
sure it is securely positioned insuch away thatno fuel
can leak out. Always remove the cutting disc before
transporting the unit in a vehicle.
- The Power Cut should be stored safely in a dry place.
It must not be left outdoors! Always dismount the
cutting disc before storage. Keep the Power Cut away
from children.
- Before long-term storage and before shipping the
Power Cut, follow the instructions in the chapter
on “Periodic care and maintenance“. ALWAYS
empty the fuel tank and run the carburetor dry.
- When putting cutting discs in storage, be careful to:
- Clean and dry them well.
- Store them lying down flat.
- Avoid dampness, freezing temperatures, direct
sunshine, high temperatures and temperature
fluctuations, as these can cause breakage and
splintering.
- Always check new cutting discs or cutting discs
that have been in storage to make sure that they
are free of defects.
Maintenance
- Before performing maintenance work switch off
the Power Cut (27) and pull out the plug cap.
- Always check the Power Cut before using it to make
sure that it is in good working order. In particular, make
sure that the cutting disc is properly mounted. Make
sure that the cutting wheel is undamaged and suitable
for the job it will be used for.
- Operate the Power Cut only at a low noise and
emission level. For this ensure the carburetor is
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adjusted correctly.
- Clean the Power Cut regularly.
- Check the fuel tank cap regularly for good sealing.
Ovserve the accident prevention instructions
issued by trade associations and insurance
companies. NEVER make any modifications to the
Power Cut! You will only be putting your own
safety at risk!
Perform only the maintenance and repair works
described in the instruction manual. All other work
must be carried out by WACKER Service.
Use only original WACKER spares and accessories.
The use of non-WACKER spares, accessories, or
cutting discs increases the risk ofaccident. Wecannot
accept any responsibility for accidents or damage
occurring in association with the use of cutting discs or
accessories other than original WACKER.
First aid
For the event of a possible accident, please make sure
that a first aid kit is alwaysimmediately availableclose
by. Immediately replace any items used from the first
aid box.
When calling for help, give the following
information:
- Place of the accident
- What happened
- Number of injured people
- Kind of injuries
- Your name!
NOTE
Individuals with poor circulation who are exposed to
excessive vibration may experience injury to blood
vessels or the nervous system.
Vibration may cause the following symptoms to occur
in the fingers, hands or wrists: “Falling asleep“
(numbness), tingling, pain, stabbing sensation,
alteration of skin colour or of the skin.
If any of these symptoms occur, see a physician!
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SERVICE
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