Panasonic Saw 999000 User Manual

GAS-POWERED CUTOFF SAW  
Item# 999000  
OWNER’S MANUAL  
Read carefully and understand RULES FOR SAFE OPERATION and instructions before  
operating. Failure to follow the safety rules and other basic safety precautions may  
result in serious personal injury.  
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Table of Contents  
Main parts and their functions  
Safety precautions  
Specifications  
3–5  
5–8  
9
Operation guide to the cutoff saw  
1. Before starting  
2. Starting  
10–13  
10–11  
11–12  
12  
3. Operation  
4. Emergency Stopping  
5. Notes on operation  
Adjustment of cutoff saw  
1. Adjusting V-belt tension  
2. Adjusting carburetor  
3. Adjusting blade guard  
Maintenance & repair of cutoff saw  
1. Cleaning and maintenance of air filter  
2. Maintenance of spark plug  
3. Replacing starter rope  
12  
12–13  
13  
13  
13  
13  
13–15  
13–14  
14  
14–15  
15  
4. Replacing pawl  
5. Maintenance chart  
16  
Storing cutoff saw  
17  
Exploded parts views and parts lists  
1. Crankshaft Housing Assembly  
2. Crankshaft & Piston Assembly  
3. Cylinder & Muffler Assembly  
4. Oil Tank & Carburetor  
18–25  
18  
19  
20  
21  
5. Handle & Main Cover Assembly  
6. Air Filter Assembly  
22  
23  
7. Cutter Assembly  
24  
8. Transmission Box & Assembly  
25  
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Main parts of the cutoff saw and their functions  
This product is composed of two main sections: a gasoline-powered 2-stroke engine and a  
driving/cutting system. When engine speed is up to 3800 RPM, the cutting blade, driven by the  
engine via a belt transmission system, begins to rotate at a high speed and is ready for cutting  
work.  
Shown below are the main parts of the cut-off saw and their corresponding function descriptions  
(Ref. Fig. 1):  
1. Blade  
2. Flanges  
4
5
6
7
8
3. Hexagon Bolt  
10  
4. Blade Guard  
9
14  
3
5. Front Handle  
6. Spark Plug Cover  
7. Kill Switch  
8. Full Throttle Lock Button  
9. Throttle Trigger  
10. Rear Handle  
13  
11  
12  
2
1
20  
11. Filter Cover Lock Lever  
12. Air Filter  
13. Choke Lever  
16  
17  
18  
15  
19  
14. Starter Grip  
15. Fuel Tank Cap  
16. Decompression Valve  
17. Water Attachment  
18. Tensioning Nut  
19. Muffler  
20. Adjusting Lever of Blade Guard  
Fig. 1  
1. Blade  
Diamond or abrasive blades. Depending on the material to be cut, these blades are made of  
different materials. Be sure to choose right blade for the material being cut. The maximum  
diameter of the blade for the saw is 14". The operating speed of the blade should be above or  
equal to 5300 RPM.  
2. Flanges  
Clamp and support the diamond or abrasive blade.  
3. Hexagon Bolt  
Tightens blade flange.  
4. Blade Guard  
Safety guard directs sparks and dust away from operator.  
3
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5. Front Handle  
Used to securely hold the saw while under operation.  
6. Spark Plug Cover  
A removable cover for access to the spark plug.  
7. Kill Switch  
Engine stops when this switch is pressed and held.  
8. Full Throttle Lock Button  
Locks the throttle in full open position by pressing this button while the trigger is fully depressed.  
Pressing and releasing the trigger returns the throttle to idle position.  
9. Throttle Trigger  
Controls engine speed by manipulating the throttle. Pulling the trigger backward opens the  
throttle and the engine accelerates. Releasing the trigger slows down the engine.  
10. Rear Handle  
Used to securely hold the saw while under operation.  
11. Filter Cover Lock lever  
Locks the air filter cover. Pull back on the lever to open the filter cover.  
12. Air Filter  
Filters dirt and debris from entering carburetor.  
13. Choke Lever  
Turning this lever counter clockwise closes the carburetor. Used to prime engine (cold starting).  
Turn clockwise for normal operation.  
14. Starter Grip  
Pull to start engine.  
15. Fuel Tank Cap  
Open this cap for filling the fuel. Close the tank for starting and operation.  
16. Decompression Valve  
Press down on this valve to make starting easier. When air pressure in the engine reaches a preset  
value, it automatically closes.  
17. Water Attachment  
Feeds water to both sides of diamond blade. Connect to water supply for wet cutting.  
18. Tensioning Nut  
For V-belt tension adjustment. Turn this nut clockwise to loosen the V-belt, turn the nut  
counterclockwise to tension the V-belt.  
19. Muffler  
Reduces both noise and emissions.  
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20. Blade Guard Adjusting Lever  
Allows adjustment of blade guard to direct dust away from operator.  
SAFETY PRECAUTIONS:  
As the cutoff saw is a high speed power tool, improper use of this saw might be  
hazardous. To avoid property damage or personal injury, it is EXTREMELY  
IMPORTANT to read, fully understand and observe the following safety  
precautions before operating this cutoff saw.  
1. Worksite Requirements:  
The worksite should be free of any materials or objects that are flammable or  
explosive.  
Surroundings should be in order, without clutter, have sufficient visibility and be  
well ventilated. The flooring the operator stands on should be nonskid. Take extreme care when  
working in wet and freezing weather (rain, snow, frost, ice).  
Bystanders should keep away from the saw when it is operating. Children, the handicapped and  
animals should never be allowed in the work area.  
Loose objects may be thrown toward the operator by the cutting tool; position the object to be cut  
securely to ensure it can’t be moved by the blade when cutting.  
2. Blade:  
Before installing a blade, make sure that the maximum operating speed of the blade  
is above or equal to the spindle speed of your cutoff saw. Inspect the cutting blade  
frequently and replace immediately if the cutting blade is cracked or warped.  
Cracked or warped blades may shatter or break and cause serious personal injury.  
Failure to follow these directions may cause the blade to shatter or crack in use,  
causing serious or fatal injury.  
Never use carbide-tipped, woodcutting or circular machine blades. They can cause severe  
personal injury from reactive forces, blade contact or thrown objects.  
Use of the wrong cutting blade for which it was not designed may cause that blade to shatter,  
causing serious or fatal injury. Only use the cutting blade approved for the type of material to be  
cut.  
Diamond blades have a much better cutting performance than standard abrasive blades. The  
blades are steel centered and diamond particles are imbedded in their cutting edges.  
Wet or dry cutting is possible. Cutting wet will extend the life of your diamond blades. A water  
attachment comes as standard equipment with this cutoff saw. Before using the water attachment,  
make sure that the screw that secures the outlet tube is tightened.  
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Always install the blade so that the arrow on the blade points in direction of the rotation of the  
spindle.  
Before carrying or transporting your cutoff saw, make sure the engine is OFF. Never leave the  
engine running while unattended (e.g. on the ground).  
Proper tension of the V-belt is important. In order to avoid a false setting, the tensioning  
procedure must be followed as described in your manual. Always make sure the hexagonal collar  
nuts for the cast arm are tightened securely. Check V-belt tension after one hour of operation and  
correct if necessary.  
3. Operator:  
The cutoff saw is a one-person tool. Start and operate this saw without assistance.  
Make sure you are in good physical condition and are not under the influence of any substance  
such as drugs or alcohol which may impair vision or dexterity. Take breaks as needed to prevent  
you from getting fatigued.  
Never let the cutoff saw run unattended. NO untrained personal should ever be allowed to use a  
cutoff machine. Bystanders, especially children and animals, should not be allowed in the area  
where a cutoff machine is in use.  
Do not lend or rent your cutoff machine without this Operation Manual. Employers should  
establish a training program for operators of this saw to ensure safe operation of this powerful  
tool.  
Avoid loose-fitting jackets, scarves, neckties, jewelry, flared or cuffed pants, unconfined long  
hair or anything that could become caught or entangled on any moving parts of the unit. Wear  
overalls or long pants to protect your legs. Do not wear shorts.  
Protect your hands with gloves when handing the cutoff saw. Heavy-duty, nonslip gloves  
improve your grip and protect your hands.  
Operate the cutoff saw with both hands, keeping a firm grip on the front and rear handles.  
Maintain good balance and footing at all times.  
Good footing is most important. Wear sturdy boots with nonskid soles. Steel-toed safety boots are  
recommended.  
To reduce the risk of injury to your eyes, never operate the cutoff saw unless  
wearing goggles or properly fitted safety glasses with adequate top and side  
protection. Proper eye protection is a must!  
Wear an approved safety hard hat to protect your head. Cutoff machine noise could  
damage your hearing: Wear earplugs or ear protectors at all times.  
Cutting masonry, concrete, metal and other materials can generate dust, mists and  
fumes containing chemicals known to cause serious or fatal injury or illness, such as  
respiratory disease, cancer, birth defects or other reproductive harm.  
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Cutting masonry, concrete and other materials with silica in their composition may give off dust  
containing crystalline silica. Silica is a basic component of sand, quartz, brick clay, granite and  
numerous other minerals and rocks. Use of an approved respirator is recommended.  
Do not cut materials containing asbestos, as asbestos dust can cause severe physical injury. Do  
not cut materials containing highly volatile or flammable substances.  
4. Inspection of the cutoff saw before use:  
1. Make sure there are no loose objects on or near the saw.  
2. Except for the carburetor adjustment screws, all other bolts, nuts, screws and the fuel tank cap  
should be securely tightened. Make sure all rubber hoses for oil flow are tightly connected with  
no leaks.  
3. Make sure the blade rotates smoothly; the starter rope can be pulled through and guided back  
without being tangled.  
4. Check to make sure the Throttle Trigger, the Full Throttle Lock Button, the Choke Lever, the  
Decompression Valve and the Kill Switch all function well without failure.  
5. Check to make sure the blade guard has no visual damage. Adjust the guard as necessary so the  
spark beam generated during cutting can be directed  
away from the operator (Ref. Fig. 2).  
6. Check to make sure the V-belt is properly tensioned.  
7. Make sure the saw is free of oil spillage.  
8. Make sure the main cover and the handles are dry  
and clean.  
9. Do not attempt to start the saw if damage is found or  
if it’s not completely and securely assembled and  
properly adjusted.  
Fig. 2  
5. Precautions on starting:  
1. Keep a good balance and secure footing.  
2. Take hold of the starter grip firmly; do not wrap the rope  
around your hand.  
3. To start, place the machine firmly against the ground and  
make sure the blade is not in contact with the ground or the  
object to be cut.  
4. Pull sharply on the rope and guide it back slowly. Do not  
let go of the grip halfway through  
the pull to prevent it from snapping back.  
Fig. 3  
6. Precautions on operation:  
1. Keep a good balance and secure footing while holding the saw firmly at all times.  
(Ref. Fig. 3)  
2. Press the throttle trigger backward slowly to make the engine accelerate gradually. Wait until  
the blade builds up the RPMs before beginning to work.  
3. Move the rotating blade slowly toward the object to be cut, increase the pressure gradually  
after the cutting edge comes in contact with the object. Make sure the cutting depth is appropriate.  
4. Do not change direction of the cut or twist during the cut as this may produce a high  
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torsion load on the blade and may cause it to break or shatter. Only move the machine along a  
straight line, forward or “to and fro” in the cutting direction.  
5. When cutting, position the saw at an appropriate distance so that your body is clear of the blade  
attachment yet you don’t have to overreach.  
6. Release the pressure on the saw when the blade completes a cut. The cutoff portion of the  
object may drop, so make sure it won’t hit any part of your body or pinch the blade.  
7. Whenever you hear an abnormal sound coming out of the cutoff saw, stop cutting immediately  
for inspection (Note the muffler and the blade are very hot at this time, so take care not to get  
burned). Only resume work after the trouble is eliminated.  
8. Do not make adjustments or perform any maintenance or troubleshooting with the cutoff saw  
while it is running.  
9. Take precaution when re-entering a cut and do not turn the blade at an angle or push it into the  
cut, as this may cause the blade to become pinched.  
7. Precautions on fueling:  
1. Fuel the machine only in a well-ventilated environment.  
2. Before refueling, let the engine cool off naturally. Do not take  
any other forceful measures to cool the engine down.  
3. Remove the fuel tank cap slowly and carefully to allow any  
pressure build-up in the tank to be released (Ref. Fig. 4).  
4. Tighten fuel cap securely after fueling and clean off spillage,  
if any.  
8. Notes on transporting:  
1. Always stop the engine before relocating the saw.  
2. When carrying the machine with a hot engine, take care not to  
have any part of your body come in contact with the muffler;  
burns could occur.  
Fig. 4  
3. Prevent the saw from touching the ground or any hard objects.  
9. Notes on maintenance:  
Perform any maintenance or repair work in clean and neat environment. Use proper tools and  
operate with caution.  
Do not attempt to modify your cutoff saw in any way. Use only identical spare parts for  
replacement.  
The cutoff saw is only intended for cutting work and cannot be used for prying or shoveling  
away any objects, or used as a grinding tool with the sides of the blade.  
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Specifications:  
Model  
Type  
1E49F (Engine Family 3ZHIS.0642CR)  
Single-cylinder, two-stroke, air-cooled  
Cylinder bore  
1.96"  
Piston stroke  
1.36"  
Displacement  
64.1 cc  
Max. output  
3.8 HP  
Speed at max. output  
Max. torque  
Idle speed  
Lock-up speed of clutch  
Min. fuel consumption  
8500 RPM  
3.5N.m  
Engine  
2400 RPM  
3800 RPM  
544 g/(kw.h)  
Minimum octane rating 93  
Two stroke engine oil  
Gasoline  
Oil  
Fuel mix  
Mix ratio 75:1  
0.4 gallons (1.5L)  
Fuel tank capacity  
Ignition type  
Electronically controlled (breakerless) magneto  
ignition  
Electrode gap of spark plug  
Spark plug thread  
0.02"  
Engine  
Blade  
M14 x 1.25; 0.38" long  
Starting method  
Rotation direction  
Diameter  
Max. operating speed  
Thickness  
Recoil start  
Clockwise  
Maximum 14"  
5300 RPM  
0.1"–0.24"  
1"  
Arbor hole diameter  
Types  
Composite abrasive blade or diamond abrasive  
blade  
Cutting depth (with thrust plate dia. Max. 4 1/2"  
4 1/2")  
Sound level  
110dB  
Overall dimensions  
(29.5" x 14" x 12")  
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Operation Guide to Cutoff Saw  
1. Before starting:  
Preparation includes clearing and arranging work surroundings, wearing proper clothing and  
protection, and inspecting the cutoff saw. In preparation, please follow the procedures described  
in the appropriate section of this manual. For additional preparation work before starting, please  
follow instructions given below:  
Fueling:  
a) Before starting, check if there is any fuel left in the fuel tank.  
b) This engine is engineered to operate on mixture of unleaded gasoline and quality two-stroke  
engine oil. Octane rating of the gasoline should at least be 93.  
c) Gas-to-oil mix ratio is 75:1.  
d) When mixing fuel, pour engine oil into the canister first, and then add gasoline (make sure the  
mix ratio is 75:1). Shake the mixture in the canister thoroughly.  
e) Clean the fuel tank cap and the area around it as necessary to ensure no dirt  
falls into the tank. Finally pour the fuel mixture into the tank and tighten fuel tank cap securely.  
f) Only mix sufficient fuel for a few days work, the maximum storage time of mixed fuel is 3  
months.  
Choosing the right blade:  
a) Blade diameter can be 12" or 14". Choose an appropriate size and type of blade which best  
suits the cutting work. Keep in mind the blade size needs to be fitted with the blade guard. The  
diameter of the arbor hole for the blade should be 1". Blade thickness should be within the range  
of .100"–.240".  
b) Blade types:  
For your reference, choose composite abrasive blades for cutting of asphalt, concrete, stone, brick,  
steel and plastics. Choose diamond abrasive blades for cutting of asphalt, concrete, stone, hard  
rock, brick, etc.  
Note: There is a rotation direction indicator marked on each diamond blade. When mounting,  
make sure it corresponds to the rotation direction of the arbor. If you are not sure which blades  
are proper for your cutting jobs, contact your dealer or distributor for information.  
c) Fitting/Replacing the blade: (Ref. Fig.5)  
Slide the locking pin (1) through the bore in the V-  
belt guard (2) (turn the blade until the locking pin  
engages in one of the bores on the belt pulley (3).  
Use the combination wrench to loosen and unscrew  
the hexagon bolt (4).  
Remove the metal washer (5), the flange (6) from  
the arbor together with the blade to be replaced.  
Fig. 5  
Mount the new blade (7).  
Fit the flange and metal washer.  
Screw in the hexagon bolt and tighten it with the combination wrench.  
Finally draw the locking pin out of the V-belt guard.  
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Tensioning the V-belt: (Ref. Fig.6):  
Loosen and unscrew the two hexagon bolts (2) on the V-belt guard (1) and then remove the V-  
belt guard.  
Loosen the three hexagon bolts (4) on the bearing plate (3).  
Turn the tensioning nut (5) clockwise until the V-belt is tensioned.  
Tighten the three hexagon bolts on the bearing plate.  
Fit the V-belt guard and fit and tighten the two hexagon bolts (2).  
Fig. 6  
2. Starting (Ref. Fig.7):  
Place the cutoff saw on the ground and make sure it’s well balanced; see to it that the saw blade  
does not touch any objects or the ground and that there is no person within the swivel range of the  
saw.  
Fig. 7  
Press the button of the decompression valve (1).  
Set the choke lever (2) to an appropriate position:  
to  
to  
if the engine is cold;  
if the engine is warm (even if the engine has already run but is still cold);  
to if the engine is warm (latched position for warm start).  
Pull the throttle trigger (3) backward as far as the stop and hold it in position.  
Press down the full throttle lock button (4).  
Release the throttle trigger (3).  
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Hold the front handle with left hand and firmly press the cutoff saw against ground, place the  
right foot on the carburetor box cover.  
Holding the starter grip (5) securely, slowly pull out the starter rope for a short distance, and then  
pull it through quickly and strongly.  
Note: Starter rope is 3 3/4-ft. long; do not pull the rope out more than its length otherwise it may  
break or cause damage to the starting system.  
• Do not let go of the starter grip.  
• After pulling, guide the rope back into place slowly.  
• Pull the rope only straight up and down through the rope guide bushing to prevent it  
from wearing.  
After the rope has been pulled through:  
• If the engine does not start, press the button of the decompression valve again and  
restart the engine.  
• If the engine runs for a while but doesn’t keep running, press the decompression valve  
in, move the choke lever to  
and then restart the engine.  
As soon as the engine is running, briefly blip the throttle trigger (3) at once. The full throttle lock  
button (4) reverts to its original position and the engine idles.  
If the engine is new, or has been stored for a long period of time, pull the starter rope through  
several times to ensure that sufficient fuel is delivered into the fuel line and combustion chamber  
of the engine.  
3. Operation:  
The blade will not run when the engine idles.  
When the cutoff saw is ready for actual cutting work, gently pull the throttle trigger (3) backward  
to accelerate the engine, when the speed is over 3800 RPM, the blade begins to rotate and speeds  
up. When the blade speed is up and stable, you can begin to move the saw slowly toward the  
object to be cut. After the cutting edge comes in contact with the object, increase pressure to the  
saw slowly until the blade is at the desired depth. Finally hold the machine securely and move  
along a straight line to complete the cut.  
To stop or halt the cut (when a cut is completed, or the engine runs out of fuel halfway, or  
abnormal sound is heard), first lift the blade out of the cut, then release the throttle trigger, wait  
until the engine slows down to idle speed and the blade stops running, then finally turn off the  
machine.  
4. Emergency stopping (Ref. Fig.8):  
Under normal conditions, the machine is to be turned off when  
the engine idles. However, if a malfunction or emergency  
occurs during cutting, you can stop the engine immediately by  
pressing and holding the Kill Switch (2) on the front end of the  
rear handle (1). But note that the service life of some  
components of the saw may be adversely affected if the engine  
is stopped too often during cutting.  
Fig. 8  
5. Notes on operation  
Follow all applicable instructions in this manual when operating the cutoff saw.  
During the break-in phase, which takes about 8 hours, the saw must not be operated at high  
speeds without load (do not pull the throttle trigger beyond 3/4 of full throttle). Following this  
procedure will lengthen the service life of your machine.  
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After the saw works for a certain period of time, let the engine idle on for a while to dissipate the  
heat. This will prevent some engine parts (ignition system, carburetor, etc.) from being damaged  
by over heating.  
ADJUSTMENT OF CUTOFF SAW  
1. Adjusting V-belt tension:  
Refer to the instruction described above in the section titled “Tensioning the V-belt.”  
2. Adjusting carburetor:  
The carburetor has been preset and adjusted at the factory to reach the optimum fuel-air mixture  
for a smooth, fuel efficient, reliable running engine with low emissions. The air  
filter and the spark plug need to be checked and maintained regularly. However, if the cutoff saw  
is found to be unsatisfactory in operation (such as the idle speed either too high or too low, or  
abnormal exhaust emission still persist), a slight adjustment on the carburetor might be necessary,  
which includes (Ref. Fig. 9):  
Standard setting adjustment:  
Find the Low Speed Adjusting Screw “L” (see Fig.9, inside  
the upper hole of the carburetor seal cover), use a screw  
driver to turn the screw L clockwise all the way to its end.  
Then turn the screw L backwards (counterclockwise) 360°.  
Adjusting idling speed:  
It is usually necessary to adjust the idle speed after Standard  
setting adjustment (above). To adjust idle speed, start the  
engine first.  
If the idle speed is too low, the engine may shut off after  
starting. In this case, make the standard setting first as  
instructed [above], then turn the idle speed adjusting screw LA  
(see Fig. 9) inside the lower hole of carburetor seal cover  
clockwise until the blade starts to run. Then turn the screw LA  
backwards (counterclockwise)  
Fig. 9  
1/4 circle (90°).  
If the idling speed is too high, the blade will run at idling speed, which is not good for the cutoff  
saw. In this case, make standard setting adjustment first, then turn the idling speed adjusting  
screw LA counterclockwise until the blade stops running. Then turn the screw  
LA 90°further (counterclockwise).  
3. Adjusting blade guard (Ref. Fig.10):  
The blade guard deflects sparks from the operator. Move the adjusting  
lever (2) to change the position of the blade guard.  
MAINTENANCE & REPAIR OF THE CUTOFF SAW  
1. Cleaning and maintenance of the air filter  
Dust and foreign build-up accumulated on the air filter may affect  
engine performance, increase fuel consumption and cause difficulty in  
starting; therefore, it is important to perform regular maintenance. The  
frequency of this depends on the conditions of the cutting jobs as well as  
Fig. 10  
material being cut both wet or dry. For dry cutting, maintenance is required every 48 hours. For  
instructions, see Fig. 11.  
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1. Set the choke lever to  
.
2. Pull the filter cover lock lever (7) backward to let the  
filter cover (1) swing open. Then take out in succession pre-  
filter (2), pre-filter (3), filter housing (4), paper air filter (5),  
and the secondary filter (6). Then clean and dry all these  
parts. Replace if any are damaged. Finally replace all of  
them in succession and close the filter cover.  
2. Maintenance of spark plug (Ref. Fig. 12):  
Wrong fuel mixture (too much engine oil in the gasoline),  
low quality gasoline or oil, dirty air filter, clogged spark  
arrestor screen, and other unfavorable running conditions  
are factors  
Fig. 11  
affecting the condition of the spark plug as they cause  
carbon  
deposit accumulation, which results in trouble in engine  
operation. Therefore, if the engine is down on power,  
difficult to start or runs poorly at idling speed, first check  
the spark plug.  
1. Remove the spark plug cover (2) on the front end of the  
main cover (1).  
2. Remove the plug boot (3) and the spark plug (4) in  
succession.  
Fig. 12  
3. Clean off the carbon build-up on the spark plug.  
4. Check electrode gap A to see if it is 0.020": readjust if necessary.  
5. Replace spark plug after approx. 100 operating hours, or earlier if the electrodes are badly  
eroded. (A BPMR7R-type spark plug is recommended for replacement.)  
6. Refit the plug boot and make sure it is snugly connected to the spark plug.  
3. Replacing starter rope (Ref. Fig. 13):  
The starter rope may need to be replaced when frayed or broken.  
1. Unscrew the screws (2) on the flywheel/starter cover (1) and remove the cover from the engine  
unit.  
2. Remove the spring clip (8), remove the rope rotor (7) with pawl (9).  
3. Using a screwdriver, unscrew the screw plug (3) on top of the starter grip, remove the starter  
rope (4) out of the grip.  
4. Put a new rope down through the grip and the rope guide bushing (5), make a simple knot at  
the end of the rope and screw in the screw plug (3)  
5. Thread the rope through the rope rotor (7) (enter from the hole on the rotor groove) and secure  
it with a simple knot.  
6. Wind the rope around the rope rotor (7) clockwise until there is a length of about 12" left  
unwound.  
7. Slip the rope rotor onto the starter post (6) and turn it back and forth a little until the anchor  
loop of the rewind spring engages.  
8. Replace the pawl (9) in the rope rotor.  
9. Press the spring clip (8) onto the starter post and over the peg of the pawl with a screwdriver.  
Note: The spring clip must point counterclockwise.  
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10. To tension the rewind spring, first guide the rope through the notch on the edge of the rope  
rotor and form a loop, use it to turn the rope rotor 4–5 times counterclockwise.  
11. Then hold the rope rotor tight, pull out the twisted rope and untangle it.  
12. Release the rope rotor, slowly let go of the starter rope so that it is wound up on the rope rotor.  
13. Refit the flywheel/starter cover (1) and screw in the four screws (2).  
4. Replacing pawl (Ref. Fig. 13):  
The pawl functions as a link between the rope rotor and the crankshaft  
(by engaging and disengaging the starter cup) and needs to be  
replaced if damaged.  
1. Unscrew the screws (2) on the flywheel/starter cover (1) and  
remove the cover from the engine unit.  
2. Remove the spring clip (8), then remove the damaged  
pawl (9).  
3. Install a new pawl.  
4. Refit the spring clip (8) and the flywheel/starter cover (1) in  
succession.  
Fig. 13  
15  
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5. Maintenance chart  
The following information refers to normal operating conditions. The specified intervals must be  
reduced accordingly when working under aggravated conditions (severe dust formation, for  
example) and with longer daily working hours.  
Complete  
Machine  
Visual  
inspection  
Clean  
Throttle trigger, Kill Functional test  
Switch  
Filter in fuel tank  
Check  
Replace  
Clean  
Fuel tank  
V-belt  
Clean  
Replace  
Clean  
Replace  
Air filter  
(all filter  
components)  
Cylinder fins  
Spark arresting  
screen  
Clean  
Inspect  
Clean or  
replace  
Check idle  
speed (the  
cutting wheel  
must not run)  
Adjust idle  
speed  
Adjust  
electrode gap  
Retighten  
in the muffler  
Carburetor  
Spark plug  
Nuts and bolts (but  
not adjusting  
screws)  
Rubber buffer  
Blade  
Replace  
Check and  
clean  
Replace  
Clean  
Support/Bracket  
16  
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Storing Cutoff Saw  
For long periods of storage:  
1. Drain and clean the fuel tank, run engine until carburetor is dry.  
2. Thoroughly clean the cutoff saw; tighten all nuts and bolts (except for adjusting screws).  
3. Remove the blade and loosen the V-belt.  
Notes on transport and storage:  
1. Avoid knocks and bumps.  
2. Abrasive blades must not be exposed to direct sunlight or other sources of heat during transport  
and storage.  
Store the machine in a place free of moisture and heat source, preferably in a place with  
consistent temperature. Do not store it near corrosive liquids.  
3. Composite blade must be protected against frost.  
The remainder of this manual provides detailed exploded parts views  
and parts lists for the cutoff saw.  
17  
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1. Crankshaft Housing Assembly  
Item  
1
2
3
4
Ref  
Description  
Screw M5×20  
Plug  
Cover  
Screw M5×20  
Washer 5  
Qty  
10  
1
1
3
1E49F01011  
1E49F01010  
1E49F01006  
1E49F01011  
GB97.1  
5
3
6
7
8
9
10  
11  
12  
13  
14  
15  
16  
17  
1E49F05000  
B1FUD1  
Coil  
1
1
1
1
1
2
1
1
1
1
1
1
Oil seal 17×28×7  
Crankshaft housing-Left  
Ball bearing 6203  
Gasket  
Positioning Sleeve  
Crankshaft housing-Right  
Oil seal 15×24×7  
Oil needle  
1E49F01001  
GB/T276-94  
1E49F01003  
1E49F01004  
1E49F01002  
B455  
1E49F01008  
GB/T276-94  
1E49F01005  
1E49F01007  
Ball bearing 6202  
Cover  
Plug  
18  
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2. Crankshaft & Piston Assembly  
Item Ref  
Description  
Flywheel/Starter  
Qty Item Ref  
Description  
1E49F02015 Piston  
1E49F02014 Piston ring  
Qty  
1
1
1E49F01009A  
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
29  
30  
1E49F03006-  
2
Screw Plug  
2
02  
GB/T5801-  
94  
Needle cage  
A4900  
3
1E49F03006  
Starter grip  
1
1E49F03006-  
4
Starter rope  
1E49F02006 Washer  
1
03  
1E49F02007-  
5
1E49F03011  
Rewind Spring  
Spring Cover  
Clutch shoe  
Retainer  
3
03  
1E49F02007-  
6
1E49F03005  
3
0
1E49F02007-  
7
1E49F03004A Rope rotor  
1E49F03009A Pawl  
Clutch  
1
06  
1E49F02007-  
8
Tension spring  
Ring  
Retainer ring  
30  
3
04  
1E49F02007-  
9
1E49F03008  
1E49F02001  
Spring clip  
Collar nut  
1
02  
GB/T893.2-  
10  
11  
12  
13  
14  
15  
1
86  
1E49F02010A Starter cup  
1E49F02002A Flywheel  
1E49F02000A Crankshaft  
GB/T276-94 Bearing 6200  
1
1E49F02007-  
01  
V-belt pulley  
1
1E49F02008 Washer  
1
Collar nut  
8 1  
1E49F02013  
1E49F02012  
Locking clip  
Piston Pin  
1E49F02009  
1
1E49F03007 Rope bushing  
1
19  
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3. Cylinder & Muffler Assembly  
Item  
1
Ref  
Description  
Qty  
1
1E49F04001  
1E49F04003  
1E49F04004  
1E49F07016  
1E49F01011  
1E49F04002-03  
1E49F04002A  
1E49F04005  
1E49F08000A  
1E49F07016  
1E49F08010  
1E49F07017  
Cylinder  
2
Spark plug  
1
3
Cylinder cover  
Screw M5×16  
Screw M5×20  
Washer  
1
4
3
5
4
6
1
7
Decompression valve  
Exhaust gasket  
Muffler Assembly  
Screw M5×16  
Muffler guard  
Screw M5×12  
1
8
1
9
1
10  
11  
12  
2
1
2
20  
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4. Oil Tank & Carburetor  
Item Ref  
Description Qty Item Ref  
Description  
Qty  
Screw  
1
1E49F01011  
8
13  
1E49F06002  
1E49F06005  
Manifold  
1
M5×20  
Oil Tank-  
Left  
Pin  
Rubber  
mount  
2
3
4
1E49FA07002  
1E49F07010  
1E49F07009A  
1
2
2
14  
15  
16  
Hose clip  
1
1
1
1E4907006-01 O-ring  
1E49F07006  
Oil Tank Cap  
5
6
7
1E49FA06005 Choke lever  
1
1
1
17  
18  
19  
1E49F07015  
1E49F07014  
Washer  
1
1
1
1E49F06003  
1E49F06001  
Air hose  
Tank vent  
Carburetor  
1E49FA07003 Gasket  
Screw  
M5×65  
Split pin  
Oil Tank-  
Right  
Oil Pick-up  
Filter  
Hose  
“U”-Rubber  
tube  
8
1E49F07020  
1E49F07011  
1E49FA07001  
2
2
1
20  
21  
22  
1E49F07012  
1E49F07005  
1E49F07007  
1
1
1
9
10  
Connecting  
Hose  
Sleeve  
11  
12  
1E49F07004  
1E49F06006  
1
1
23  
24  
1E49FA06002 Screw bracket  
1E49FA06001 Screw M4×5  
1
1
21  
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5. Handle & Main Cover Assembly  
Item Ref  
Description  
Main Cover  
Side sealing cover  
Front sealing cover  
Spark plug cover  
Kill switch  
Qty  
1
1
1
2
1E49FA09001  
1E49F09016  
1E49F09013  
1E49FA09002  
1E49FA5001  
GB/T845- 85  
1E49FA09010  
1E49F09010-03  
1E49F09010-02  
1E49FA09003  
1E49F09006  
1E49FA09008  
GB/T845-85  
3
1
4
1
5
1
6
Screw ST2.9×13  
Handle molding  
Torsion spring  
Full throttle lock button  
Throttle trigger  
Trigger pin  
2
7
1
8
1
9
1
10  
11  
12  
13  
14  
15  
1
1
Fixed block  
1
12_1E49F060×13  
Throttle triggering wire  
Flameout Wire  
1
1E49FA06002  
1E49F05004  
1
1
22  
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6. Air Filter Assembly  
Item  
1
2
3
4
5
6
7
8
Ref  
Description  
Filter cover  
Pre-filter  
Qty  
1
1
1
1
1
1
2
1
1
1
2
1
1
1
1
1
1E49FA1004  
1E49F1003-02  
1E49F1003-01  
1E49FA10001  
1E49F10006  
1E49F10007A  
GB/T845-85  
1E49FA10003  
1E49FA10002  
1E49F06007  
1E49F07016  
1E49F10010  
1E49FA10005  
1E49FA10006  
GB119-1986  
1E49F07012  
Pre-filter  
Filter housing  
Paper Air Filter  
Secondary filter  
Screw ST2.9×19  
Half round  
9
Filter base  
Gasket  
10  
11  
12  
13  
14  
15  
16  
Screw M5×16  
Flat spring  
Filter cover lock level  
Torsion spring  
Pin B3×32  
Screw M5×12  
23  
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7. Cutter Assembly  
Item Ref  
Description  
Qty Item Ref  
Description  
Qty  
EHS400-  
01010  
EHS400-  
01011  
EHS400-  
01013-C  
EHS400-  
01014  
EHS400-  
01015  
1
Hexagon bolt  
Washer  
1
1
2
1
2
1
1
1
2
1
1
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
GB/T65-85  
GB68-85  
Screw M6×6  
1
2
Screw M6×12.5  
Tension spring  
Tension bush  
Screw  
1
4
4
4
1
1
2
1
1
1
EHS400-  
01019  
EHS400-  
01018  
EHS400-  
01020  
EHS400-  
01004A  
EHS400-  
01021A  
3
Flange  
4
Blade clamp  
Washer  
5
EHS400-  
01016  
6
Inner Rubber ring  
Blade Guard (400mm)  
Handle  
Support  
EHS400-  
01006A  
EHS400-  
01007A  
EHS400-  
01026  
EHS400-  
01017  
EHS400-  
01022-D  
7
Ring  
8
GB/T276-94  
Ball bearing 6202  
Belt Pulley  
Washer  
EHS400-  
01008  
9
Screw M6×16  
Outer Rubber ring  
Shaft  
10  
11  
GB1797-85  
EHS400-  
01009  
NUT M10×1-Left  
EHS400-  
01005  
GB/T96-85  
EHS400-  
01031  
12  
13  
14  
GB/T1099-79 Woodruff key 4×13  
1
2
1
27  
28  
29  
Pulley Cover  
Washer 8  
1
2
2
GB/T893.2-86 Clip 35  
EHS400-  
Block  
Screw M8×22  
01003-02  
EHS400-  
Block arm  
01003-01  
EHS400-  
01002  
15  
1
30  
Screw  
3
24  
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8. Transmission Box & Assembly  
Item Ref  
Description  
Qty Item  
Ref  
Description  
Qty  
EHS400-  
02007A  
Transmission  
box  
EHS400-  
03003-01A  
EHS400-  
03003-02A  
GB97.2-85 Washer 8  
1E49F070  
1
1
12  
Support  
1
2
3
4
1E49F01006  
1E49F07019  
1E49F01010  
Cover  
3
3
3
13  
14  
15  
Wheels  
2
2
2
Screw M6×16  
Plug  
screw M5×25  
18  
GB894.1-  
86  
1E49F070  
21  
EHS400-  
03001A  
1E49F070  
17  
EHS400-  
03002  
1E49F070  
19  
5
1E49F01011  
Screw M5×20  
Clamping lever  
Cover  
5
1
1
2
1
1
2
16  
17  
18  
19  
20  
21  
22  
Spring lock 8  
Screw M5×24  
Handle frame  
Screw M5×12  
Handle bracket  
Screw M6×16  
2
2
1
2
1
1
1
EHS400-  
02005A  
EHS400-  
02006A  
6
7
8
1E49F07017  
Screw M5×12  
9
EHS400-02008 V-belt  
EHS400-  
02001A  
EHS400-03003-  
03  
10  
11  
Belt Tensioner  
EHS400-  
02009  
Transmission  
box cover  
Wheel shaft  
25  
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