Wacker Neuson BTS 930L3 Repair Manual

BTS 930L3BTS 935L3BTS 1030L3BTS 1035L3Item number 0208118Repair ManualEdition 03/06

2 Safety instructions8 Cutting discs2.5 Cutting discs• The protective hood must always be attached. Change the cutting disc only when the motor has be

10 Maintenance98 Cleaning/Changing the air filter10.6 Cleaning/Changing the air filter• Turn the cover lock (11) to the "unlocked" position

10 Maintenance99 Cleaning/Changing the air filter• Take the prefilter (17) out of the filter cover.• Pull the air filter cartridge (18) out of the ho

10 Maintenance100 Cleaning/Changing the air filter2. Air filter cartridge (paper cartridge)• The air filter cartridge (2) filters the intake air throu

10 Maintenance101 Replacing the spark plug10.7 Replacing the spark plug• The spark plug must be replaced if the ceramic insulator is damaged, or if t

10 Maintenance102 Replacing the spark plug1. Ignition test• Insert the combination wrench (3) between the hood and cylinder, as shown in the figure.•

10 Maintenance103 Replacing the suction head10.8 Replacing the suction head• The felt filter (13) of the suction head can become clogged during opera

10 Maintenance104 Miscellaneous10.10 Miscellaneous1. Cutting attachment in the center/outer positionNote: The cutting attachment is mounted at the fac

10 Maintenance105 Miscellaneous• Pry out the stop pin (7) with the combination wrench (8) far enough, as shown in the figure, so that you are able to

10 Maintenance106 Miscellaneous• Place the cover (15) on top.• Screw on the nuts (16) and tighten by hand.• Tighten the V-belt, see Chapter "Tigh

11 Torque values10711 Torque values* = in lb1 ft lb = 1.357 Nm 1 inch = 25.4 mmTypeft lb Nm ft lb Nm ft lb Nm inch Met. inch Met.M3 *11 1.2 *14 1.

2 Safety instructions9 Cutting discs• The cutting disc must be approved for freehand cutting with a 350 mm (14") cutting disc diameter up to 437

11 Torque values108

2 Safety instructions10 Cutting discs• When operating the cut-off saw, hold it firmly with both hands. The right hand on the rear handle, and the left

2 Safety instructions11 Kickback and pulling motion2.6 Kickback and pulling motion• When working with the cut-off saw, it can kick back or suddenly p

2 Safety instructions12 Maintenance2.7 Maintenance• Before you carry out any maintenance work, always turn off the cut-off saw (10) and pull off the s

3 Starting up133 Starting up• Always use the assembly tools included in delivery for the following proce-dures:• Set the cut-off saw onto a sturdy ba

3 Starting up14 Attaching the cutting disc3.1 Attaching the cutting discNote: Check the cutting disc for signs of damage. See the safety instructions

3 Starting up15 Fuel, lubricants, and coolants3.2 Fuel, lubricants, and coolantsFuel mixture• The cut-off saw engine is a high-performance two-cycle

3 Starting up16 Fuel, lubricants, and coolants• For optimum engine performance and for the sake of your own health and the environment, always use lea

3 Starting up17 Storing fuel3.3 Storing fuel• Fuels cannot be stored indefinitely. Purchase only enough fuel as you can possibly use in 4 weeks.• Sto

3 Starting up18 Filling the tank3.4 Filling the tankNote: Strictly observe the safety instructions in the operator's manual!• Fuels must be handl

3 Starting up19 Starting the engine3.5 Starting the engineNote: Strictly observe the safety instructions in the operator's manual.• The cut-off

3 Starting up20 Cold start3.6 Cold start• Press the multifunction switch (5) upward (choke position).• Put your hand around the handle (safety switch

3 Starting up21 Warm start3.7 Warm start• As described under cold start, however without pressing the multifunction switch (5) in the choke position.

3 Starting up22 Setting the carburetor3.9 Setting the carburetorNote: The cut-off saws are equipped with a speed limiting electronic ignition. In addi

4 Technical data234 Technical dataUnitBTS 930L3BTS 935L3BTS 1030L3BTS 1035L3Item no. 0008987...0610073...0008988...0610074...0008989...0610075...0008

4 Technical data241) Data takes the operating states idle and top speed equally into consideration.2) Peripheral speed at the highest engine speed.3)

5 Special tools255 Special toolsItem no. Designation Item no. Designation0068900 Magnet wheel puller 0117575 Piston ring band clamps0079264 Pressure

5 Special tools26

6 Disassembly27 Cover/Handle6 Disassembly6.1 Cover/HandleItem Designation Item Designation Item Designation1 Handle 7 Side brace 13 Pulley2 Cover 8 T

Contents0208118en_001IVZ.fm 11 Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 Disassembly28 Cover/Handle1. Unscrew the 3 screws (8,9) and take off the side brace (7) and handle (1).2. Unscrew the Torx screws (11,15) and take o

6 Disassembly29 Clutch6.2 ClutchCS = Clutch sideItem Designation Item Designation Item Designation1 Exhaust 7 Crankcase half (CS) 13 V-belt2 Torx scr

6 Disassembly 30 Clutch1. Unscrew the Torx screws (15) out of the cover (14) and take off the cover (14).2. Take off the V-belt (13).3. Unscrew the T

6 Disassembly31 Clutch6. Loosen the clutch (12) with installation wrench (0117574) and a 19 mm ring wrench (x). Note: Left-hand thread!7. You can re

6 Disassembly 32 Clutch

6 Disassembly33 Recoil starter6.3 Recoil starterItem Designation Item Designation Item Designation1 Starter handle 6 Air horn 11 Torx tapping screw2

6 Disassembly 34 Recoil starter1. Unscrew the screws (2).2. Take off the starter housing (3). 3. Unscrew the screws (11) and carefully separate the a

6 Disassembly35 Recoil starter6. The replacement return spring is delivered already under tension in the housing (z).7. To change the starter ratchet

6 Disassembly 36 Recoil starter

6 Disassembly37 Filter cover/Filter6.4 Filter cover/FilterItem Designation Item Designation Item Designation1 Bayonet cap 5 Lower part of the plug 9

Contents0208118en_001IVZ.fm 28.6 Filter cover/Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 778

6 Disassembly 38 Filter cover/Filter1. Open the bayonet cap (1) and take off the filter cover (2) with the prefilter (3).2. Remove the seal rings (4,

6 Disassembly39 Ignition system module/intake manifold6.5 Ignition system module/intake manifoldItem Designation Item Designation Item Designation1 S

6 Disassembly 40 Ignition system module/intake manifold1. Take the ignition cable and short circuit cable (10,1) out of the guides (x) of the hood (2

6 Disassembly41 Ignition system module/intake manifold5. Unscrew the screws (3,5) and remove the hood (2). 6. The screw (5) also functions as the fas

6 Disassembly 42 Ignition system module/intake manifold11. Lift the intake manifold (16) from the tank enclosure by pressing the lever (x).12. Lift t

6 Disassembly43 Ignition system module/intake manifold13. Pull the short circuit cable (1) out of the seat in the choke shaft (18). 14. Release the g

6 Disassembly 44 Ignition system module/intake manifold

6 Disassembly45 Tank6.6 TankItem Designation Item Designation Item Designation1 Parallel pin 5 Handle shell 9 Fuel cap2 Throttle lever lock 6 Vent va

6 Disassembly 46 Tank1. Only if it becomes necessary, press in the vent valve (6) into the tank (x) with a mandrel and take it out through the filler

6 Disassembly47 Cylinder/Crankshaft6.7 Cylinder/CrankshaftCS = Clutch side MS = Magnet sideItem Designation Item Designation Item Designation1 Decomp

1 Foreword31ForewordIn the interest of your own safety and to prevent accidents, you should carefully read through the safety instructions, familiari

6 Disassembly 48 Cylinder/Crankshaft1. Unscrew the screws (16) from the cylinder (2).2. Pull the cylinder (2) with cylinder base gasket (6) off of th

6 Disassembly49 Cylinder/Crankshaft6. Unscrew the decompression valve (1) and check the valve seat as well as the bore in the cylinder (2) for dirt.

6 Disassembly 50 Cylinder/Crankshaft

6 Disassembly51 Vibration dampers6.8 Vibration dampersMS = Magnet side CS = Clutch sideItem Designation Item Designation Item Designation1 Torx screw

6 Disassembly 52 Vibration dampers1. Unscrew the Torx screw (1) from the crankcase half (MS) and remove the disc (2).2. Press the axle (4) out of the

6 Disassembly53 Protective hood/V-belt pulley6.9 Protective hood/V-belt pulleyItem Designation Item Designation Item Designation1 Hexagonal bolt 8

6 Disassembly 54 Protective hood/V-belt pulley1. Unscrew the screw (1) and remove the thrust washer (2).2. Block the V-belt pulley (15) by inserting

6 Disassembly55 Protective hood/V-belt pulley5. Unscrew the screws (17) with springs (18) from the thrust collar (5).6. Take off the entire protect

6 Disassembly 56 Protective hood/V-belt pulley

7 Disassembly/Inspection57 Carburetor/Inspection7 Disassembly/Inspection7.1 Carburetor/InspectionItem Designation Item Designation Item Designation1

1 Foreword4

7 Disassembly/Inspection58 Carburetor/Inspection1. To disassemble the control side, unscrew the screws (10), carefully take off the cover (9), control

Carburetor Inspections 7 Disassembly/Inspection59 Carburetor/Inspection8. For cleaning purposes, you can take out the carburetor fuel screen (5) out

7 Disassembly/Inspection60 Carburetor/Inspection

8 Assembly61 Protective hood/V-belt pulley8 Assembly8.1 Protective hood/V-belt pulleyItem Designation Item Designation Item Designation1 Hexagonal bo

8 Assembly62 Protective hood/V-belt pulley1. Attach the outer retaining clip (13). 2. Heat the cutting attachment (19) to approx. 100 °C (use industri

8 Assembly63 Protective hood/V-belt pulley9. Set the inner thrust washer (2) and the distance bushing (4) onto the axle (3).10. Insert the axle (3) i

8 Assembly64 Protective hood/V-belt pulley

8 Assembly65 Vibration dampers8.2 Vibration dampersMS = Magnet side CS = Clutch sideItem Designation Item Designation Item Designation1 Torx screw 3

8 Assembly 66 Vibration dampersNote: Apply grease to the vibration dampers (3) before you install them.MS crankcase:1. Press the axle (4) with the co

8 Assembly67 Cylinder/Crankshaft8.3 Cylinder/CrankshaftCS = Clutch side MS = Magnet sideItem Designation Item Designation Item Designation1 Decompres

2 Safety instructions5 Proper use2 Safety instructions2.1 Proper use1. Cut-off saw• The cut-off saw must only be used outdoors for cutting/cutting to

8 Assembly 68 Cylinder/CrankshaftNote: The exposed side of the ball bearing (8) faces the crankshaft. Apply Omnifit 100M to the ball bearings on the

8 Assembly69 Cylinder/Crankshaft6. Set the crankcase halves (9,13) together and screw them together with the Torx screws (15). Tighten the screws cro

8 Assembly 70 Cylinder/Crankshaft13. Place the piston support from the set of piston rings (0117575) onto the crank-case and set the piston (3) on to

8 Assembly71 Tank8.4 TankItem Designation Item Designation Item Designation1 Parallel pin 5 Tank 9 Fuel cap2 Throttle lever lock 6 Vent valve 10 Suct

8 Assembly 72 Tank1. Insert the suction hose (10), attach the suction head (7).2. Screw in the fuel cap (9) and seal (8).3. Mount the throttle lever

8 Assembly73 Ignition system module/intake manifold8.5 Ignition system module/intake manifoldItem Designation Item Designation Item Designation1 Shor

8 Assembly 74 Ignition system module/intake manifold1. Clean the cone (x) of the crankshaft and magneto flywheel.2. Set the magneto flywheel (19) ont

8 Assembly75 Ignition system module/intake manifold10. Screw the carburetor (17) onto the intake manifold (16) (torque wrench setting 1.5 ± 0.5 Nm).1

8 Assembly 76 Ignition system module/intake manifold19. Press in the hook (w) of the spring (8) into the center of the ignition cable (10) from the t

8 Assembly77 Filter cover/Filter8.6 Filter cover/FilterItem Designation Item Designation Item Designation1 Bayonet cap 5 Lower part of the plug 9 Int

2 Safety instructions6 Fuel, Lubricants, and Coolants / Filling the tank2.3 Fuel, Lubricants, and Coolants / Filling the tank• Before you fill the tan

8 Assembly 78 Filter cover/Filter1. Lay the internal filter (9) into the intake manifold (x).2. Set the air filter cartridge (8) onto the internal fi

8 Assembly79 Recoil starter8.7 Recoil starterItem Designation Item Designation Item Designation1 Starter handle 6 Air horn 11 Torx tapping screw2 Tor

8 Assembly 80 Recoil starter1. Apply bonding compound to the bolt (9).2. Press the bolt (9) with springs far enough to create a gap of 0.15 - 0.20 mm

8 Assembly81 Recoil starter7. Pass the rope through the recess (x) on the rope drum (5) and, together with the rope, turn the rope drum (5) twice in

8 Assembly 82 Recoil starter

8 Assembly83 Clutch8.8 ClutchItem Designation Item Designation Item Designation1 Muffler 7 Crankcase half 13 V-belt2 Torx screw 8 Snap ring 14 Cover3

8 Assembly 84 Clutch1. Attach the snap ring (8) in the groove of the crankshaft.2. Attach the stopping ring (18) with recess to the snap ring (8) and

8 Assembly85 Clutch9. Remove the stop wedge.10. Attach the guard (6) directly on the cylinder, then screw on the seal (5) and muf-fler (1) with Torx

8 Assembly 86 Clutch

8 Assembly87 Cover/Handle8.9 Cover/HandleItem Designation Item Designation Item Designation1 Handle 7 Side brace 13 Pulley2 Cover 8 Torx screw 14 Tor

2 Safety instructions7 Starting up2.4 Starting up• Do not work alone; someone must be nearby in case of an emergency (within calling distance).• Whe

8 Assembly 88 Cover/Handle1. Screw on the bushing (12) and the pulleys (13) to the foot (16) using the Torx screw (14).2. Fasten the handle (1) and f

9 Malfunction899 MalfunctionMalfunction System Observation CauseCutting disc does not startClutch Engine is running Clutch is damagedCutting disc rot

9 Malfunction90

10 Maintenance91 Maintenance schedule10 Maintenance10.1 Maintenance scheduleUsers of cut-off saws are only permitted to carry out the maintenance and

10 Maintenance92 Maintenance scheduleEntire cut-off saw Clean the outside and check for damage. If damage is discovered, have it repair by qualified p

10 Maintenance93 Cleaning the protective hood10.2 Cleaning the protective hood• With time, material deposits will form on the inside of the protectiv

10 Maintenance94 Replacing the V-belt10.3 Replacing the V-belt• Loosen the nuts (3).• Loosen the tension screw (1) (counterclockwise) until you see th

10 Maintenance95 Tightening the V-belt10.4 Tightening the V-beltNote: To obtain the maximum cutting performance at the lowest fuel con-sumption, it i

10 Maintenance96 Carburetor setting10.5 Carburetor setting1. To make the basic setting, carefully turn the idle jet "L" inward as far as it

10 Maintenance97 Carburetor settingDue to the exhaust emission standards currently in effect, the L and H adjusting screws of the unit are not access