BCS PowerSafe 770HY User manual

Operang Instrucons
Before commissioning the machine, read operang instrucons and
observe warning and safety instrucons.
PLEASE ALSO READ ORIGINAL
BCS INSTRUCTION MANUAL
PowerSafe® Two Wheel Tractors
Manufactured by BCS S.p.A.
Model 770HY

BCS 770HY Two Wheel Tractor Power Unit
Page 2 TWT770HY/PU/0221
Contents
Page 3 Safety Symbols and Warnings
Page 5 Safety
Page 8 Idencaon and Sckers/Labels
Page 9 Sckers/Labels
Page 10 Assembly Instrucons
Page 11 Controls Descripon
Page 12 Making Adjustments
Page 13 Aaching Implements
Page 14 To Start the Machine (Honda Petrol Engine)
Page 16 To Start the Machine (Yanmar Diesel Engine)
Page 18 Operaon
To Stop Engine
Page 19 Maintenance Guide
Storage
Page 20 Service Informaon
Page 22 Maintenance Programme
Sound & Vibraon Levels
Page 23 Troubleshoong Guide
Page 24 OPC Operang Cable Adjustment
Page 25 Risk Assessment
Page 26 Service Record
Page 27 Manufacturer’s Informaon
IMPORTANT!
READ THIS MANUAL
CAREFULLY
!

BCS 770HY Two Wheel Tractor Power Unit
TWT770HY/PU/0221 Page 3
SAFETY ALERT SYMBOL
This indicates important safety
messages. When you see this symbol,
be aware of the possibility of injury,
carefully read the message that
follows, and inform other operators.
MANUAL OPEN
This means that you must carefully read
the user and maintenance manual.
NO! DO NOT DO!
This means that you must absolutely
not carry out the operaons stated
below this symbol. It could involve a
lethal hazard.
IMPORTANT!
You must pay parcular aenon to
the following informaon.
NOTE
Used to draw aenon to addional
informaon given on a specic topic.
Do not repair or lubricate the machine
when the parts are moving or the
engine is on.
Do not smoke. Do not light matches
or ames. Do not leave naked ames
around or make sparks.
Take special care not to touch hot parts
of the engine.
Engine exhaust fumes can cause
sickness or death. If it is necessary to
run an engine in an enclosed area, use
an exhaust pipe extension to remove
the fumes. Always try to work in a well
venlated area.
Cauon! Never touch moving pulleys
or belts. They can be very dangerous.
Never undertake maintenance with
engine running.
A burst which separates the tyre from
the rim parts can cause serious injury
or death.
Prevent baery explosions: keep
sparks, lighted matches and open
ames away from the top of the
baery. Baery gas can explode.
Handle fuel with care, it is highly
ammable: do not refuel machine
while smoking, when machine is near
an open ame or sparks, or when the
engine is running. Stop the engine.
Sulfuric acid in baery electrolyte is
poisonous. It is strong enough to burn
skin, eat holes in clothing and cause
blindness if it gets in contact with the
eyes.
Rotang blades and moving
implements are dangerous. Protect
children and prevent accidents.
Avoid pping. Do not drive where
machine could slip or p. Stay alert for
holes and other hidden objects.
Safety Symbols and Warnings

BCS 770HY Two Wheel Tractor Power Unit
Page 4 TWT770HY/PU/0221
Before using the machine it is mandatory to put on the correct personal
protecve equipment (PPE): body protecon, protecon gloves, security
shoes, and ear protecon.
DANGER!
Machine rollover: don’t use this machine on slopes greater than 30°
(58%).
WARNING!
SHARP PARTS. Keep hands and feet away. Do not
operate with people near the machine, foreign bodies
may be ejected by blades or rotang parts, generang
a danger. Keep people away. Remove the key and read
the instrucon manual before aempng to carry out
any maintenance or repairs to the machine.
Safety Symbols and Warnings

BCS 770HY Two Wheel Tractor Power Unit
TWT770HY/PU/0221 Page 5
Read the user manual carefully before
starng up the engine. The following
warnings are important for the safety
of the operator and any onlookers or
pets.
Cauon and common sense are the
main factors in accident prevenon.
Do not use the machine on slopes
exceeding 30o (58% of inclinaon).
Warning! The machine should only be
used for the purpose for which it was
designed. Do not transport persons. Do
not make changes to it or tamper with
it. Do not race with it at all or use it as
a trailer, etc.
Pay parcular aenon to the warnings
and safety sckers on the machine.
Cauon! Danger! The baery contains
sulphuric acid. Fatal if ingested! It can
cause blindness if it gets into contact
with eyes. It can also burn the skin and
dissolve clothing.
Danger! Keep the baery away from
sparks, matches, lighted cigarees
and naked ames. The baery gas is
extremely dangerous and lethal. Can
explode.
Cauon! Danger! An exploded tyre can
cause serious injuries or death.
Danger! The fuel is highly ammable.
Do not refuel when the engine is on.
Turn o the engine. Let the muer
cool down. Do not refuel while smoking
or in the vicinity of naked ames or
sparks. Handle and store the fuel with
care.
Danger! Never touch moving pulleys
and belts. Can cause serious accidents
to people.
Danger! Do not carry out maintenance
with the engine on. Turn o the engine
and remove the key.
Following the inial start-up, it is
recommended that you familiarize
yourself with the controls and the
machine.
Prior to starng work, learn how to turn
o the machine safely and quickly.
Danger! The movement of blade and
fork is verv dangerous. Never put your
hands and/or feet near the blade and
forks.
Before leng other people use your
machine, you must inform them about
the safety standards. Make them read
the user manual and teach them how
to use the machine.
Before turning on the machine, check
that there is nobody in the vicinity,
especially children.
Before reversing the machine, check for
people or obstacles.
Safety

BCS 770HY Two Wheel Tractor Power Unit
Page 6 TWT770HY/PU/0221
Danger! Do not use the machine when
red. Do not drink alcohol.
Check the ground before to cut. Check
for stones, scks or foreign bodies,
which could be catch from blade
or rotang parts and became very
dangerous.
Danger! Do not work on overly sloping
ground where the machine could slide
or p over.
Before commencing work, wear
appropriate work clothing, gloves,
protecve footwear and glasses.
Before geng down from the machine,
turn o the engine, disable the PTO,
remove the ignion key and lower the
implement to the lowest posion.
Travel slowly on bumpy roads.
Slow down on downhill slopes.
Danger! Must not be used by people
under the age of 18 years and by non-
experts.
Danger! Do not reverse with
accelerated engine.
When engine is at full power, it is
dangerous to turn suddenly.
Danger! Do not make sudden
movements with the forwards or
backwards lever.
To avoid the danger of toxic exhausts,
do not use the engine indoors when
turned on.
Fill the fuel tank before starng up the
engine. Only refuel outdoors. Always
turn o the engine. Stay away from
sparks or ames. Do not smoke. Do
not remove the fuel tank cap when the
engine is hot. Safely close the tank cap
and the fuel containers.
Avoid fuel leaks. Aer having lled
the tank dry all fuel resi-dues on the
machine before starng the engine.
Danger! Do not use the machine near
ditches or piers that may give way
under the weight of the machine,
especially when the surface is friable
or wet.
Always take downhill bends slowly.
Danger! Do not tamper with or disable
the safety devices.
Danger! Do not work with persons near
the machine, foreign objects they may
be launched by the blades or rotang
parts, making it very dangerous.
When the machine is not in use, remove
the keys from the panel and store them
in a place inaccessible to children.
Danger! Do not carry out any type
of adjustments or cleaning when the
engine is in operaon.
Safety

BCS 770HY Two Wheel Tractor Power Unit
TWT770HY/PU/0221 Page 7
Danger! Do not have the machine
checked by other people while seated
at the steering wheel with the engine
in operaon.
The user is always responsible for
damage caused to third pares.
All improper use will cause the warranty
to expire and the manufacturer shall
not be held liable.
Broken blades and deformed teeth
must always be replaced, never
repaired.
Always use original spare parts and
accessories.
Only work in daylight or in good
arcial light.
Danger! Do not stop on slopes or when
working uphill or downhill.
If you have to empty the fuel tank, do
the operaon out-doors.
CAUTION! To lower the risk of re, keep
the engine, muer, exhaust manifolds,
baery, tank area and fuel pipes free
from grass, leaves, dust, etc.
Danger! Do not store the machine in
buildings where fuel fumes could come
into contact with ames. sparks and
unsheathed electrical wires.
Always replace the worn or damaged
muers.
Keep the fuel in designated containers.
Never keep the fuel in food-grade
containers.
Pay parcular aenon to persons and
occasional passers-by when working
near roads.
Danger! Never work with persons
around the machine. Always maintain a
safety distance.
Danger! Do not tamper with the engine
sengs, especially the maximum
number of revoluons.
If you hit a foreign body, disengage
the PTO, stop the engine, remove the
ignion key and inspect the machine.
If the machine vibrates, take it to
Tracmaster or an Authorised Dealer to
have it checked.
Let the engine and muer cool down
before moving the machine indoors.
Safety

BCS 770HY Two Wheel Tractor Power Unit
Page 8 TWT770HY/PU/0221
Idencaon and Sckers/Labels
An idencaon label is applied to every machine in accordance with the EC Machinery Direcve (g. 1a).
See g. 1b for its locaon on the machine.
1. Brand
2. Manufacturer
3. Model
4. Engine
5. Engine power (kW)
6. Weight (kg)
7. Year of manufacture
8. Serial number
IMPORTANT! Preservaon of the Labels
The labels must be kept clean from dust and mud.
Labels must always be clearly visible and legible.
Labels must be replaced if they are missing or illegible.
In the case of a replacement part or implement for the machine, or replacement of any components that
were originally equipped with labels, it is imperave that the labels are present, so they must be replaced
if they are missing or illegible.
The labels are available on the parts diagram specic to each machine model.
New labels may be obtained from the Spare Parts Department at Tracmaster Ltd or through your Authorised
Dealer.
Fig. 1a
Fig. 1b

BCS 770HY Two Wheel Tractor Power Unit
TWT770HY/PU/0221 Page 9
Sckers/Labels
1. CE idencaon
2. Steering controls
3. Read the user manual
4. Engine on/o
5. Slow/fast speed
6. PTO engagement
7. Throle control
8. PowerSafe® operaon
9. Raise/lower handlebar
10. Foward/reverse indicator
11. Unlock the parking brake
12. Hot surfaces
13. Risk of explosion
14. Filter maintenance
15. Decompression (diesel engine)
16. Engine operaon (diesel engine)
17. Made in Italy
18. BCS logo
19. 770HY model
20. Dierenal lock
21. PowerSafe® logo

BCS 770HY Two Wheel Tractor Power Unit
Page 10 TWT770HY/PU/0221
Assembly Instrucons
1. Remove the machine from its packing case.
2. Rotate the handlebar stem to the operang posion and t the handlebars - check operaon and
roung of cables.
3. Fit the wheels, ensuring the correct rotaon (see diagram) and check the tyre pressures (20psi).
4. Fit the gearbox dipsck.
5. Check the engine oil level.
6. Follow the instrucons in both this manual, and the original BCS manual, to run the machine.

BCS 770HY Two Wheel Tractor Power Unit
TWT770HY/PU/0221 Page 11
L
A
G
Controls/Devices Descripon
Model 770HY
(A) OPC LEVER (red lever that stops the machine when released)
(B) ENGINE STOP LEVER
(C) CLUTCH CONTROL LEVER
(D) GEAR LEVER (the locaon of dierent gears are shown on the selector)
(E) PTO LEVER (there is a safety device that prevents engagement with reverse gear)
(F) THROTTLE LEVER
(G) HANDLEBAR HEIGHT ADJUSTMENT LEVER
(H) STEERING COLUMN SWIVEL LEVER
(L) FORWARD/REVERSE LEVER (always engage the clutch before engaging this lever)
(M) DIFFERENTIAL LOCK LEVER
(N) PARKING BRAKE LEVER
(O) RIGHT BRAKE LEVER
(P) LEFT BRAKE LEVER
B
O
P
C
NM
D
H
F
E
Fig. 2

BCS 770HY Two Wheel Tractor Power Unit
Page 12 TWT770HY/PU/0221
Making Adjustments
The machine is delivered with the correct adjustments,
however, if it is necessary to make adjustments, then
this should be done via the adjusng screws below or
on the handlebar:
PowerSafe® clutch cable adjustment (g. 3a, 1).
Brake cables adjustment (g. 3b, 2).
Throle cable adjustment (g. 3c, 3).
Engine stop cable adjustment (g. 3c, 5).
Engine RPM adjustment (g. 3c, 6) (see engine
manual).
Forward/reverse knob cable adjustment (g. 3d, 4).
Fig. 3d 4
Fig. 3b 2
Fig. 3a
1
Fig. 3c
6
3
5

BCS 770HY Two Wheel Tractor Power Unit
TWT770HY/PU/0221 Page 13
Aaching Implements
Implements are either mounted directly to the ange (g. 4a, 1) or coupled with the quick release assembly
(g. 4b, 2) .
It is important that nuts (g. 4b, 3) which fasten the implement and the bushing are well ghtened.
Fig. 4a Fig. 4b
2
3
1

BCS 770HY Two Wheel Tractor Power Unit
Page 14 TWT770HY/PU/0221
To Start the Machine (Honda Petrol Engine)
Pre-Operaon Checks
Before starng the engine ensure the gear lever (g. 2,
D) is in neutral posion and the power take-o (PTO)
lever is disengaged (g. 2, E) .
Using the dipsck provided check the engine oil level.
Top up with 10w/40 oil if necessary.
Check the gear oil level (see service informaon on
page 20 for more details).
Check fuel level.
Only use unleaded petrol from a clean container. Avoid
the use of contaminated, old or poorly preserved fuel.
The manufacturer and retailer assume no responsibility
for damage to the unit due to poor quality and poor
preservaon of the fuel by the owner of the machine.
Never re-fuel when the engine is hot or running.
Leave 1” air space in the fuel tank.
Check that the air lter is clean, if not then it must be
cleaned or replaced.
Check that safety equipment, including guards, is clean
and free from obstrucons.
Check that the handlebar adjustment is working, by
using the lever (g. 2, H) and moving the handlebars to
the side posion.
To Start the Engine
Check that the stop lever (g. 5a, 1) is in the ON posion
( I ).
Turn the fuel valve lever (g. 5b) to the ON posion.
If the engine is cold set the choke lever (g. 5c) to the
CLOSED posion.
To restart a warm engine leave the choke lever in the
OPEN posion.
Accelerate lightly with the throle lever - move it
forward approximately one-third (g. 5d, 1).
Fig. 5b
Fig. 5a
1
Fig. 5c
1
Fig. 5d

BCS 770HY Two Wheel Tractor Power Unit
TWT770HY/PU/0221 Page 15
To Start the Machine (Honda Petrol Engine)
For recoil-start engines:
Pull the starter grip lightly unl you feel resistance, then
pull briskly in the direcon of the arrow as shown (g.
5e).
Return the recoil starter grip gently .
IMPORTANT! To avoid damage to the starter
do not allow the starter grip to snap back
against the engine.
If the choke lever was moved to the CLOSED posion
(g. 5c) to start the engine, gradually move it to the
OPEN (g. 5g) posion as the engine warms up.
For electric-start engines:
Turn the key to the START posion (g. 5f) , and hold it
there unl the engine starts.
If the engine fails to start within 5 seconds, release the
key, and wait at least 10 seconds before operang the
starter again.
IMPORTANT! Using the electric starter for
more than 5 seconds at a me will overheat
the starter motor and can damage it.
When the engine starts, release the key, allowing it to
return to the ON posion.
If the choke lever was moved to the CLOSED posion
(g. 5c) to start the engine, gradually move it to the
OPEN (g. 5g) posion as the engine warms up.
Fig. 5e
Fig. 5f
Fig. 5g

BCS 770HY Two Wheel Tractor Power Unit
Page 16 TWT770HY/PU/0221
Before starng the engine ensure the gear lever (g. 2,
D) is in neutral posion and the power take-o (PTO)
lever is disengaged (g. 2, E) .
Using the dipsck provided (g. 2b, 22) , check the
engine oil level.
Top up with 10w/40 oil if necessary.
Check the gear oil level (see service informaon on
page 20 for more details).
Check fuel level.
Only use diesel from a clean container.
Never re-fuel when the engine is hot or running.
Leave 1” air space in the fuel tank.
Make sure the fuel cock is in the ON posion (g. 6a, 1) .
Turn the engine speed control lever (g. 6b, 1) to the
RUN posion (g. 6b, 2).
IMPORTANT! Every 30-40 days start the
engine and let it run for a few minutes to keep
the injector and the pump operang, and to
prevent it from scking.
For recoil-start engines:
Push the decompression lever on top of the engine (g.
6c, 1) and release it.
The lever will automacally return to the original
posion when the engine starts.
Grasp the recoil starter handle (g. 6d, 1) .
Pull the handle all the way out with a strong and even
moon, use two hands if necessary.
Slowly return the recoil starter handle to the inial
posion.
If the engine does not start, repeat this procedure again.
1
Fig. 6c
2
Fig. 6b
1
To Start the Machine (Yanmar Diesel Engine)
1
Fig. 6a
Fig. 6d
1

BCS 770HY Two Wheel Tractor Power Unit
TWT770HY/PU/0221 Page 17
For electric-start engines:
Make sure the fuel cock is in the ON posion (g. 6a, 1) .
Turn the engine speed control lever (g. 6b, 1) to the
RUN posion (g. 6b, 2).
Insert the key into the key switch (g. 6e) .
Turn the key clockwise to the START posion (g. 6e, 1) .
Release the key as soon as the engine starts, it will
return to the ON posion (g. 6e, 2) .
IMPORTANT! If the engine fails to start wait
unl it comes to a complete stop before
aempng to start it again. Engaging the
starter while the engine is sll rotang will
result in damage to the starter motor and
ywheel.
IMPORTANT! Wait at least 30 seconds before
you aempt to start the engine again. This
pause will allow the baery voltage to recover
and prevent damage to the starter motor due
to the low baery voltage.
To Start the Machine (Yanmar Diesel Engine)
Fig. 6e
1
2

BCS 770HY Two Wheel Tractor Power Unit
Page 18 TWT770HY/PU/0221
Operaon
See g. 2 on page 11.
Use handlebar adjuster (G) to set handlebar height.
Hold the handlebar and pull up the clutch lever (C).
Depress the OPC lever (A) and select the correct working speed using the gear lever (D).
Ensure forward/reverse lever is in the correct posion to move forward (L):
If the handlebars are posioned over the engine then this lever should be in the fully back posion.
If the handlebars are posioned over the implement then it should be in the fully forward posion.
Engage drive to the working implement by using the PTO lever (E):
If the handlebars are posioned over the engine then pull the PTO lever (E) towards you.
If the handlebars are posioned over the implement then push the PTO lever (E) away from you.
Release clutch lever (C) slowly and fully, keeping the red machine stop lever depressed as the machine will
stop if released.
Move the throle lever to the correct posion for the implement you are operang - please refer to the
Implement Manual.
Commence work
Close the throle (F).
Engage clutch lever (C).
Locate gear lever (D) in neutral posion.
Disengage drive to the digging knives by pulling the PTO lever (E) backwards.
Release clutch lever (C).
Release the OPC lever (A) completely.
Move the engine stop lever (B) to posion O ‘STOP’.
WARNING: THE EXHAUST COVER MAY BE HOT - DO NOT TOUCH.
To Stop Engine

BCS 770HY Two Wheel Tractor Power Unit
TWT770HY/PU/0221 Page 19
For engine maintenance please refer to engine manufacturers manual.
Aer every hour of operaon stop the engine and remove the spark plug cap.
Check engine oil level (recommended oil SAE 15w/40).
Replace the spark plug cap.
Do not turn the machine on its side for cleaning.
Before checking the oil level ensure the machine is level.
Remove the gearbox unit dipsck and ensure the oil reaches the top level mark, if necessary top up with
SAE 15w/40 gear oil (see page 20).
If the machine is not be used for a long period of me it is advisable to take the following precauons:
• Empty the carbureor and fuel tank (refer to engine manual for details). Alternavelty, add a fuel
stabiliser.
• Empty the engine of oil.
• Petrol engine: lubricate the cylinder with a few drops of engine oil through the plug hole then turn
the engine over several mes without starng it.
• Diesel engine: remove the injector by unscrewing the two bolts which fasten it to the head and
pour a lile oil into the hole.
• Clean the engine and the machine thoroughly.
When restarng check that all security devices are working.
Maintenance Guide
Storage

BCS 770HY Two Wheel Tractor Power Unit
Page 20 TWT770HY/PU/0221
Service Informaon
Every Week
• With the machine on a level surface, check the gearbox oil level, top up as necessary using the
correct oil as listed below. The gearbox oil level should reach between the two notches on the
dipsck (g. 8, D) .
Aer the First 2 Weeks or 30 Hours of Work
• Replace the gearbox oil lter ONLY, (g. 7, A), part number 580C0268.
• Check the gearbox oil level using the dipsck (gs. 7 & 8, C) , run the machine for 2-3 minutes and
recheck gearbox oil level, top up as necessary using the correct oil as listed below.
Every 100 Hours of Work or 12 Months
• Change the gearbox oil by removing the gearbox drain plug (g. 3, B) .
• Replace the gearbox oil lter (g. 7, A), part number 580C0268.
• Clean the gearbox drain plug and ret.
• Fill gearbox using the correct oil and quanty as listed below.
• Check the gearbox oil level, run the machine for 2-3 minutes and recheck gearbox oil level.
To replace the oil lter (g. 7, A)
1. Using the correct spanner, remove the
lter.
2. Smear a lm of oil on the rubber gasket of
the new lter.
3. Mount the new lter, screwing and
ghtening by hand only.
Fig. 7
A
C