Bormann Pro BTC5118 Concrete Cutter

Specifications

Safety Instructions

General Safety

• Read and understand the entire manual before operating or servicing the equipment.
• Not for use by persons under 18 years of age.
• Always wear appropriate protective clothing, shatterproof glasses, steel-toed boots, and other required safety gear.
• Do not operate when feeling unwell, fatigued, or under the influence of medication, drugs, or alcohol.
• Use only company-recommended accessories and attachments.
• Do not operate or service the equipment without proper guards and safety devices in place.
• Keep inexperienced and unauthorized personnel away from the equipment.
• Unauthorized modifications will void all warranties.
• Always check the machine for loose threads or bolts before starting.
• Never touch hot exhaust manifold, muffler, or cylinder; allow parts to cool before servicing.
• Allow the engine to cool before adding fuel or performing service; hot components can cause burns.
• Ensure adequate free flow of cooling air to the engine.
• Never operate in enclosed or narrow areas where air flow is restricted; this can cause serious damage and injury. Remember the engine emits deadly carbon monoxide gas.
• Always refuel in a well-ventilated area, away from sparks and open flames.
• Exercise extreme caution with flammable liquids; stop the engine and allow it to cool before refueling.
• Do not smoke around or near the machine; fuel vapors or spills can cause fire or explosion.
• Never operate in an explosive atmosphere or near combustible materials; an explosion or fire could result in severe injury or death.
• Topping off fuel filler port is dangerous; it tends to spill fuel.
• Never use fuel as a cleaning agent.
• Always ensure the operator is familiar with proper safety precautions.
• Stop the engine when leaving the cutter unattended.
• Block the unit when leaving or using on a slope.
• Maintain the equipment in safe operating condition at all times.
• Always stop the engine before servicing, adding fuel, or oil.
• Never run the engine without an air filter; severe engine damage may occur.
• Service the air cleaner frequently to prevent carburetor malfunction.
• Store equipment properly when not in use, in a clean, dry location out of reach of children.
• Never operate this cutter in areas containing combustible material or fumes; sparks can cause explosions.

Diamond Blade Safety

• Use appropriate steel-centered diamond blades manufactured for concrete cutters.
• Inspect diamond blades before each use for cracks, dings, or flaws. Ensure the center hole is undamaged and has accurate model dimensions.
• Examine blade flanges for damage, excessive wear, and cleanliness before mounting.
• Ensure the blade fits snugly on the shaft and against the inner/outer blade flanges.
• Ensure the blade's operating speed rating is greater than the cutter's shaft speed.
• Cut only the material specified for the diamond blade.
• Always keep blade guards in place; blade exposure should not exceed 180 degrees.
• Ensure the diamond blade does not contact the ground or surface during transportation.
• Do not drop the diamond blade.
• The engine governor is set for maximum engine speed under no-load conditions. Speeds exceeding this limit may cause the blade to exceed its maximum safe allowable speed.
• Ensure the blade is mounted for proper operating direction.

Cutter Transportation Safety

• Use the lifting bail and appropriate lifting equipment for safe movement.
• Do not use handle bars or front pointer as lifting points.
• Never tow the saw behind a vehicle.
• Position pointer bars appropriately to minimize exposure during transport.
• Avoid extreme cutter attitudes relative to the lever; engine tilt can cause oil to gravitate into the cylinder head, making starting difficult.
• Never transport the cutter with the blade mounted.

Operation

Operating Principle

Periodic maintenance of this unit is essential for long and trouble-free use. Read the manual in its entirety and follow instructions carefully to avoid injury.

Delivery Checks

• Read the manual completely.
• Check the general condition of the equipment for shipping damage.
• Check engine oil level.
• Check fuel levels.

Installing Blade

1. Ensure the spark plug is disconnected or the saw is unplugged.
2. Remove the blade shaft nut and the outer blade shaft flange.
3. Clean any foreign particles from flange contact surfaces and the blade mounting surface.
4. Position the blade on the shaft, aligning the offset drive pin in the blade with the drive pin in the mounting collar (if applicable). If the blade has a directional arrow, position it for cutting downwards.
5. Place the outer blade shaft flange onto the shaft. The drive pin on the inner collar must project through the drive in the blade and into the outer collar (if applicable).
6. Tighten the blade shaft nut securely against the star washer and outer flange using a wrench.
7. Reconnect the spark plug or plug in the electric supply cord (with the switch off).

Types of Cutting

• Cut speed depends on using the correct blade for the material. Diamond blades for wet or dry cutting of concrete or asphalt are available.

Before Starting

• Use the correct blade for the cutting conditions.
• Ensure arbors and flanges are clean and undamaged.
• Mount the blade and tighten securely with a wrench.
• For wet cutting, check water jets for adequate flow.
• Align the pointer with the cutter blade.

Caution: Set the unit up in an open area. Avoid close proximity to structures or other equipment. Failure to do so may cause inadvertent injury to the operator or other persons in the area.

Starting the Engine

• Cold Start: Open the fuel valve fully. Set the engine stop switch to 'run'. Open the throttle about halfway and apply the choke. Pull the starter rope sharply. Once the engine starts, open the choke and adjust the throttle as needed to keep it running. Allow the engine to warm up for a few minutes before placing it under load. If the engine doesn't start after three pulls, slightly open the choke to prevent flooding. Always operate the engine at full throttle when under load.
• Hot Start: Open the fuel valve fully if it was shut off. Open the throttle about halfway. Do not apply the choke. Pull the starter rope sharply until the engine starts. Once the engine starts, adjust the throttle. Always operate the engine at full throttle when under load.
• Gasoline Engine Caution: To improve engine service life, allow the engine to idle without load for 2-5 minutes before shutting it down. When the idling period is up, use the stop switch to turn off the engine. Close the fuel valve. Engine flooding can occur if the valve is left open during transport.

To Start Cutting

1. Start the engine and let it warm up. All cutting is done at full throttle.
2. Align the blade and cutter with the cut. For wet cutting, open the water valve and turn on the water safety switch.
3. Lower the blade into the cut slowly.
4. Cut as fast as the blade allows. If the blade climbs out of the cut, reduce forward speed or depth of cut.
5. Use only enough side pressure on the cutter handles to follow the cutting line.

Cutting

Lower the blade into the concrete to the required depth by turning the tilt crank counterclockwise. Ease the saw forward slowly. Slow forward pressure if the saw begins to stall.

Note: For deeper cuts (4 inches/102mm or more), make several cuts in incremental steps of 1-1/2 inches (38mm) to 2 inches (51mm) until the desired depth is reached. Push the saw steadily forward, using the front pointer as a guide. Exert enough forward pressure so that the engine/motor begins to labor but does not slow down. If the saw stalls, retard forward movement until full RPM is restored to the blade. If the saw stalls, raise the blade out of the cut before restarting. Avoid excessive side pressure or twisting the blade in the cut.

Belts and Pulleys

NEVER MAKE ADJUSTMENTS TO V-BELTS AND PULLEYS WHILE THE ENGINE IS RUNNING

1. The best tension for a v-belt drive is the lowest tension at which the belts will not slip under full load.
2. Increase tension until belts are snug in grooves. Run the drive for about five minutes to seat the belts. If belts slip, tighten them until they no longer slip at peak load. Most new belts will need additional tensioning after seating.
3. Excessive tension shortens belt and bearing life.
4. Check belt tension frequently during the first day of operation. Check periodically thereafter and make necessary adjustments.
5. Common causes of sheave misalignment: a) Engine drive shaft and blade shaft are not parallel. b) Pulleys are not located properly on shafts.
6. Use a steel straight edge to check alignment (See Figure 1).
7. Align the straight edge along the outside face of both pulleys. All pulleys have two set screws in their grooves; these require threadlocker.
8. Misalignment will show as a gap between the pulley face and the straight edge. Ensure clearance between the pulley and the saw base on both sides.

Figure 1: Belt and Pulley Alignment

[Diagram showing pulley alignment with a straight edge]

Troubleshooting

Lubrication and Service

• Check oil levels, wiring, hoses (air, fuel, water) and lubricate the machine daily.
• Repair or replace all worn or damaged components immediately.
• Check drive belt tension; do not over-tension.
• Ensure the machine has a full set of matched belts.
• Check the blade shaft; ensure the arbor and threads are not worn, damaged, or bent.
• Blade shaft bearings should be tight, with no side-to-side or up-and-down play.
• Grease blade shaft bearings daily.
• Blade collars should be clean, free of nicks and burrs, with no diameter wear and not out of round.
• Drive pin should not be excessively worn or bent and free of gouges.
• All guards must be in place and secure.
• All fasteners must be tight and secure.
• Air filter/oil filter (hydraulic or engine) must be clean.
• Flush the pump with clean water and spray the assembly every night to prolong pump and blade life.
• Clean the machine before starting lubrication maintenance.
• Ensure the machine is on solid, level ground before starting maintenance.
• Observe strict cleanliness at all times during lubrication maintenance.
• Use the correct tool for the job and keep tools clean to avoid accidents.
• Draining engine oil is best done when the oil is warm, not hot.
• Clean up any spilled oil immediately.
• Use only clean containers for oil and only clean, fresh oils and grease of the correct grade.
• Dispose of contaminated water/fluids/oil/filters safely.