Beton Trowel BTCS500 User manual

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INSTRUCTION MANUEL
SLAB SAW
BTCS500

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Use this guide along with the parts lists attached to locate and identify components of
your trowel. When ordering replacement parts, be sure to provide the model number
and serial number from the trowel.
Copyright
© Copyright 2011 by Beton Trowel.
Contact
BETON TROWEL
Nijverheidsstraat 11
1840 Londerzeel
BELGIUM
www.betontrowel.com

Beton Trowel nv
Nijverheidsstraat 11
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BETON TROWEL NV
Nijverheidsstraat 11
B-1840 Londerzeel
Declares that this product :
Floor Saw BTCS500
Chris Livingston
Managing Director

Beton Trowel nv
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Foreword
Quality assurance / machine break in
The machine is the product of extensive engineering development designed to give long life
and unmatched performance. The trowels are shipped fully assembled, and only require
filling with fuel and a brief check of lubricant levels in preparation for operation.
You can help ensure that your trowel will perform at top levels by observing a simple routing
on first use. Consider that your new trowel is like a new car. Just as you would break in a
new car to the road or any new machine to the job, you should start gradually and build up to
full use. Learn what your machine can do and how it will respond. Refer to the engine
manufacturer’s manual for run-in times. Full throttle and control may be used after this time
period, as allowed by material. This will serve to further break in the machine on your specific
application, as well as provide you with additional practice using the machine.
We thank you for the confidence you have placed in us by purchasing a
Beton Trowel machine and wish you many years of satisfied use.

Beton Trowel nv
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Beton Trowel nv
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2 General description of the BTCS500
Any modification, which could lead to a change in the original characteristics of the
machine,
may be done only by Saint-Gobain Abrasives S.A. who shall confirm that the machine is still in
conformity with the safety regulations. Saint-Gobain Abrasives S.A. keeps the right of making
technical or design modification without prior notification.
2.1 Short description
The Floor Saw BTCS500 you have chosen, is used for small repair works in concrete and
asphalt, for cutting induction loops and installing cables as well as for cutting expansion joints. It
can be used for either wet or dry cutting operations. Being of small construction, it can be
transported in a car or van. The water container is enclosed in the frame. All component parts on
the BTCS500 are assembled to a high quality standard, ensuring long life, reliability and
a minimum of maintenance. Special types of blades are available for asphalt, green concrete,
cured concrete (reinforced or not) as well as for industrial cement flooring.
Made of jig welded open profile steel, the BTCS500 is stable but at the same time,
easily transportable.
The one-piece blade guard fully protects the operator and his working environment. It
is
firmly fixed to the main frame but can be opened by rotation to change blades.
A manually operated hand wheel mechanism enables graduated depth setting. Turning the
hand wheel clockwise or anti-clockwise will lower or raise the cutting blade.
The pivoting frame , hinged on the rear axle, is supporting the engine, the blade
shaft
assembly, and the protecting guards. Four heavy-duty belts drive the blade.
The precisely manufactured blade shaft is fitted into two heavy-duty self-aligning pillow
block bearings, including grease nipples. A four-belt taper lock pulley is fitted on one end. The
shaft is reduced to 25,4mm at the other end, allowing an inner flange complete with dowel
pinholes to be fixed.
The steel belt guard is bolted to the mainframe of the machine. It is covering the four
drive
belts and pulleys for protection of the environment while the machine is running. The pointer
allows the operator to make precise cut easily.
The Honda GX390 engine is connected to an emergency shut down switch on the
board of
the machine. This allows an immediate stop of the machine in case of danger. The water
cooling system is composed of a 70 litres water tank, a water tank tap and two water nozzles
on the blade guard ensuring adequate flow of water to both sides of the blade.

Beton Trowel nv
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2.3 Technical data
Engine
Honda GX390, 4 strokes, 1 cylinder, 13HP (9,6kW)
Fuel
Automotive unleaded gasoline
Oil
Honda 4-Stroke, or equivalent high detergent, premium quali t y
motor oil certified to meet or exceed U.S. au t omobile
manufacturer’s requirement for service classification SG, SF. (SG ,
SF designated on the oil con t ainer) .
SAE 10W-30 recommended
Starter
Manual pull chord
Air filter
Dual type (machine type 99277, 99556, 99557, and 99558)
Cyclone type (machine type 99939)
Max. blade diameter
500 mm
Bore
25,4 mm
Max. cutting depth mm
190 mm
Flange diameter
115 mm
Blade shaft speed
2600 min
-1
Driving belts
4
Water tank
70 l
Machine dimensions
(length x width x height)
1088x580x925mm
Weight
140 kg
Max. operating weight
220 kg
Sound pressure level
89 dB (A) following ISO EN 11201
Sound energy level
105 dB (A) following ISO EN 3744

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3 Assembly and commissioning
Before beginning the work with the BTCS500, you have to assemble some
parts.
3.1 Tool assembly
Only use professional blades with the BTCS500
.
A blade with a maximum diameter of 500 mm can be fitted. All tools used must be selected with
regard to their maximum permitted cutting speed for the machine’s maximum permitted rotation
speed.
Before mounting a new blade, switch the machine off.
To mount a new blade, follow these
steps:
Turn the wheel until the cutting head is in the raised position.
Loosen the screw maintaining the blade guard with the 19mm wrench, and turn it open.
Loosen the hexagonal nut, which holds the removable outer flange with the 36mm wrench.
Remove the outer flange.
Clean the flanges and blade shaft and inspect for wear.
Mount the blade on the shaft ensuring that direction of rotation is correct. Wrong direction of
rotation blunts the blade quickly.
Replace outer blade flange.
Tighten hexagonal nut with spanner supplied for this purpose.
Close the blade guard.
The blade bore must correspond exactly to the blade shaft. Cracked or damaged bore
is
dangerous for the operator and for the machine.
3.2 Water cooling system
Fill the water tank with clean
water.
Open water-tap (note that handle on water-tap should be in line with water-flow).
Ensure that water is flowing freely in the circuit and delivered adequately to both sides of the
blade, as insufficient water supply may result in premature failure of the diamond blade.
In case of frost, empty the water cooling system

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3.3 Starting the machine
Make sure the blade is raised clear up the ground before starting the machine.
Turn the fuel valve to the ON position.
Move the choke lever to the CLOSED position.
NOTE: do not use the choke if the engine is
warm or the air temperature is high.
Move the throttle control lever slightly to the
left.
Put the engine switch on ON, and make sure
the emergency switch on the board of the
machine is in the correct position.
Pull the starter grip lightly until you feel
resistance, then pull briskly.
CAUTION: Do not allow the starter grip to snap
back against the engine. Return it gently to
prevent damage to the starter.
As the engine warms up, gradually move the
choke lever to the OPEN position.
Position the throttle control lever for the
maximum engine speed.
To stop the engine, move the throttle control lever fully to the right, then turn the engine switch to
the OFF position. Turn the fuel valve to the OFF position

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4 Transport and Storing
Take the following measures in order to transport and store the BTCS500 securely
4.1 Securing for transport
Before transporting the
machine:
Remove the blade.
Empty the water tank.
Raise the guide-a-cut in its upright position.
Raise the cutting frame to its highest position using the handwheel.
4.2 Transport procedure
The machine can be moved on a flat surface using its wheels. Use the metal hook located
on
the board of the machine over the motor to move the machine with a crane.
4.3 Long period of inactivity
If the machine is not going to be used for a long period, please take the following
measures:
Completely clean the machine.
Loosen the drive belts. Grease
the threaded shaft. Possibly
change the motor oil. Empty
the water system.
The storage site must be clean, dry and at a constant temperature

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5 Operating the BTCS500
5.1 Site of work
Before you start working, please check the following points:
Remove from the site anything, which might hinder the working procedure.
Make sure the site is sufficiently well lit.
Make sure you have a continual adequate view of the working area so you can intervene in
the working process at any time.
Keep other staff out of the area, so you can work securely.
5.2 Cutting method
5.2.1 Preparing your
cut
Before starting the machine,
Draw a line on the floor over the cutting length.
Make sure you have filled the engine tank with fuel, and the water tank with water. No petrol
is supplied with the machine.
The engine is shipped with oil. Check oil level before starting. Top up if required.
Make sure you have mounted the correct blade as recommended by the manufacturer
depending on the material to be worked, the working procedure (dry or wet cut) to be carried
out, and the efficiency required.
Make sure that the flanges securely hold the diamond blade.
Make sure that the blade is not touching the floor before starting.
Roll the machine until the blade is over the line.
Lower the guide-a-cut so it touches the line.
5.2.2 Cutting the
floor
You can now start the engine.
To make your cut,
Turn the depth hand wheel until the blade slightly touches the floor.
Open water valve to control the amount of water required for the type of blade, using 15 to
25l/min for wet and 1-2l/min for dry cutting, dust control. Check for minimum water level
regularly.
turn the hand wheel to lower blade into the cut.
Once the required depth of cut is reached, push the machine forward with steady and gentle
pressure and follow the line with the pointer. The feed speed must be adjusted depending
on the material being cut, and depth of cut.
At the finish of the cut, raise the blade out of the cut by turning the hand wheel, switch off the
engine and shut-off the water

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After one hour of work
Begin of the day
During the changing of the tool
End of the day
Every week
After a fault
After a damage
Whole machine
Visual control (general aspect,
watertightness)
Clean
Flange and blade fixing devices
Clean
Belts tension
Control
Water hoses and nozzles
Clean
Depth screw
Grease
Engine housing
Clean
Reachable nuts and screws
Tighten up
6 Maintenance and service
ATTENTION : to perform maintenance on the machine, always switch it off. Always wear a face
mask and safety goggles while performing the maintenance of machine
6.1 Maintenance of the machine
To ensure a long-term quality from the cutting with the BTCS500, please follow the
maintenance plan below:
Adjustment and replacement of the
belts
After one hour of work, the belts heat and stretch. Therefore, you have to re-tension
them.
To adjust the belts, firstly remove the belt guard by unscrewing the 2 nuts. Loose the 2 bolts
at the back of the engine-plate and shift the engine by using the screw on the back of the plate
to retighten the belts.
To replace the belts, move the engine completely down by unscrewing the screw at the back
of the engine-plate. Adjust the belts and retighten them using the screw at the back of the
engine plate.
Always use a matched set of belts. Do not replace single belts. After controlling or
retightening
the belts, reassemble the belt guard on the frame of the
machine.
Lubrication
The BTCS500 uses life-lubricated bearings. Therefore, you don’t need to lubricate
them at all. Grease the depth screw every day.

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Cleaning of the
machine
Your machine will last longer if you clean it thoroughly after each day of work
6.2 Maintenance of the engine
Each use
First month or 20 hours
Every 3 months or 50 hours
Every 6 months or 100 hours
Engine oil
Check level
Change
Air cleaner filter
Check
Clean
Fuel strainer cup Clean
Spark plug Check-Clean
Fuel line Check (Replace if necessary)
Every 2 years

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8. PARTS

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