BTS 930L3 BTS 935L3 BTS 1030L3 BTS 1035L3 Repair Manual Item number 0208118 Edition 03/06
Contents 1 Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2.1 Proper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2.2 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2.
Contents 8.6 8.7 8.8 8.9 Filter cover/Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recoil starter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cover/Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 79 83 87 9 Malfunction . . . . .
1 Foreword 1 Foreword In the interest of your own safety and to prevent accidents, you should carefully read through the safety instructions, familiarize yourself with them, and observe them at all times. The safety of the operator was one of the most important aspects taken into consideration when this machine was designed. Nevertheless, improper use or incorrect maintenance can pose a risk. Please operate and maintain your Wacker machine in accordance with the instructions in the operator's manual.
1 Foreword 4
2 Safety instructions 2 Safety instructions 2.1 Proper use 1. Cut-off saw • 2. Non-approved work methods: • 3. The cutting discs of the cut-off saw must not be used as a grinding tool (removing material with the side surface of the cutting disc). This may cause the disc to break! It is prohibited to attach saw blades, knives or brushes to the cut-off saw. Non-approved operators: • 2.
2 Safety instructions 2.3 Fuel, Lubricants, and Coolants / Filling the tank • • Before you fill the tank, go to a a safe and level area. It is prohibited to fill the tank on a scaffolding, a mound of material or similar elevated structure! Turn off the motor before you fill the tank of the cut-off saw. 1 • • • • • • • Smoking and open fires are not permitted (1). Let the motor cool down before you fill the tank. Fuels can contain solvent-like substances.
2 Safety instructions 2.4 Starting up • • • Do not work alone; someone must be nearby in case of an emergency (within calling distance). When using cut-off saws in residential areas, please observe the local noise regulations. Do not use the cut-off saw near combustible materials or explosive gases. There is a risk of sparking.
2 Safety instructions 2.5 Cutting discs • • The protective hood must always be attached. Change the cutting disc only when the motor has been turned off! If you are using diamond-edged cutting discs, make sure you observe the attached rotational direction mark. 5 • Cutting discs are only designed to cut materials on their edges. Never use the side surfaces for grinding purposes as this can break the disc (5)! 6 Note: • • min.
2 Safety instructions • The cutting disc must be approved for freehand cutting with a 350 mm (14") cutting disc diameter up to 4370 rpm or 80 m/s (260 ft./sec) or with a 300 mm (12") cutting disc diameter up to 5100 rpm or 80 m/s (260 ft./sec). Use only cutting discs that comply with EN 12413, EN 13236 or with the BGV D 12. 7 • • • The cutting disc must be completely undamaged (7). Test it by performing a sound test with a piece of wood.
2 Safety instructions • When operating the cut-off saw, hold it firmly with both hands. The right hand on the rear handle, and the left hand on the bow handle grip. Hold the grips firmly using your thumbs. CAUTION When you release the throttle lever, the cutting disc will continue to run briefly (afterrun) • • • Always ensure that you are standing in a secure position. Hold the cut-off saw in such a way that you cannot inhale the exhaust fumes.
2 Safety instructions 2.6 Kickback and pulling motion • When working with the cut-off saw, it can kick back or suddenly pull you. Please see the relevant pages in the operator's manual.
2 Safety instructions 2.7 Maintenance 10 • • • • • • Before you carry out any maintenance work, always turn off the cut-off saw (10) and pull off the spark plug connector! Check that the cut-off saw is in a safe operating condition before you start work. Make sure that the cutting disc has been attached according to instructions. Alos make sure that the cutting disc is undamaged and suited for the application at hand.
3 Starting up 3 Starting up CAUTION Before working on the cut-off saw, always turn off the engine, pull off the spark plug connector and wear protective gloves! CAUTION The cut-off saw must not be started until it has been completely assembled and tested! • Always use the assembly tools included in delivery for the following procedures: 1. Combination wrench 13/19 mm 2. Offset screwdriver 3.
3 Starting up 3.1 Attaching the cutting disc Diagram Note: • Check the cutting disc for signs of damage. See the safety instructions in the operator's manual. Unscrew the screw (9) and remove the thrust washer (8). Set the cutting disc (5) onto the shaft (7). Note: The center hole of the cutting disc must fit exactly onto the shaft. You must use an adapter ring if the center hole is larger.
3 Starting up 3.2 Fuel, lubricants, and coolants DANGER The unit uses mineral oil products (gasoline and oil)! Take special precautions when handling gasoline. Smoking and open fires are not permitted (danger of explosion). Fuel 50:1 + 1,000 cm3 (1 liter) 5,000 cm3 (5 liter) 10,000 cm3 (10 liters) 1.0 Us-gal. 2.5 Us-gal. 5.0 Us-gal. 20 cm3 100 cm3 200 cm3 2.5 floz. 6.4 floz. 12.8 floz. Preparing the correct gasoline/oil mixing ratio: 50:1 Mix 50 parts of fuel with one part of oil.
3 Starting up • • For optimum engine performance and for the sake of your own health and the environment, always use leadfree fuel! The two-cycle motor oil must meet the specification API TC, JASO FC or ISO L-EGD. Note: To prepare the fuel-oil mixture, always premix the prescribed amount of oil volume with half of the fuel volume and then add the remaining amount of fuel. Before you fill the tank, always shake the finished mixture well.
3 Starting up 3.3 Storing fuel • • Fuels cannot be stored indefinitely. Purchase only enough fuel as you can possibly use in 4 weeks. Store fuel only in approved and specially marked containers. AVOID CONTACT WITH SKIN AND EYES! • • Mineral products and oils scour your skin. If used repeatedly and over time, they will dry out your skin. This could develop into one of various skin diseases. In addition, allergic reactions are also possible. Oil in your eyes can cause irritations.
3 Starting up 3.4 Filling the tank Fuel mixture Note: • • • • • • • Strictly observe the safety instructions in the operator's manual! Fuels must be handled carefully and prudently. Only when the engine is turned off and has cooled down! Clean the filling area so that no dirt can get into the tank. Set the machine on its side on a flat base. Screw off the tank cap and pour in the fuel mixture. Pour it in carefully to avoid spilling the fuel mixture. Tightly screw the tank cap back on.
3 Starting up 3.5 Starting the engine if required Note: • • • • • Strictly observe the safety instructions in the operator's manual. The cut-off saw must not be started until it has been completely assembled and tested! Take it at least 3 m (10 feet) away from the place where you filled the tank! Stand squarely and set the cut-off saw onto the ground so that the cutting attachment is freestanding. Move the protective hood (3) to the best position for the application at hand (see figure).
3 Starting up 3.6 Cold start • • • • • • • • Press the multifunction switch (5) upward (choke position). Put your hand around the handle (safety switch (7) is actuated by the palm of your hand) Press the throttle lever (8) all the way through and hold it. Press the lock button (6) and release the throttle lever (8) (throttle lever is locked in place by the lock button in the half-gas position). Press in the start valve (4).
3 Starting up 3.7 Warm start • 3.8 As described under cold start, however without pressing the multifunction switch (5) in the choke position. Turning off the engine • Press the multifunction switch (9) down to the "Stop" position.
3 Starting up 3.9 Setting the carburetor Set the idle speed with a flathead screwdriver (head width 4 mm/0.16"). The screwdriver shown has a moulded nose that can be used as a setting tool. Note: The cut-off saws are equipped with a speed limiting electronic ignition. In addition, the carburetor has a fixed nozzle that cannot be adjusted. • The idle speed has been factory set to approx. 2500 rpm; however, the runin procedure of a new machine requires a slight readjustment of the idle speed.
4 Technical data 4 Technical data Unit Item no. BTS 930L3 BTS 935L3 BTS 1030L3 BTS 1035L3 0008987... 0610073... 0008988... 0610074... 0008989... 0610075... 0008990... 0610076 Engine displacement m³ 64 73 Bore mm 47 50 Stroke mm Max. performance kW 3.3 4.2 Max. torque Nm 4.0 5.
4 Technical data BTS 930L3 Unit BTS 935L3 Gasoline/2-cycle oil mixing ratio 5) BTS 1030L3 BTS 1035L3 50:1 Cutting disc for max. 80 m/s 2) mm 300/20.0/ 53) 350/25.4/ 53) 300/20.0/ 53) 350/25.4/ 53) Spindle diameter mm 20.0 25.4 20.0 25.4 Weight of cut-off saw (empty tank, without cutting disc) kg 10.0 10.2 10.0 10.2 1) Data takes the operating states idle and top speed equally into consideration. 2) Peripheral speed at the highest engine speed.
5 Special tools 5 Special tools 0068900 0079264 0117574 0117571 0117575 0128935 0128936 0128937 Item no. Designation Item no.
5 Special tools 26
6 Disassembly 6 Disassembly 6.
6 Disassembly 1. Unscrew the 3 screws (8,9) and take off the side brace (7) and handle (1). 7 8 1 9 2. Unscrew the Torx screws (11,15) and take off the foot (10 or 16). 3. Unscrew the Torx screw (14) only for item 16, dismantle the bushing (12) and take out the pulleys (13). 4. Loosen the flanged nut (5) and unscrew the tension screw (3) far enough so that the screw end does not make contact with the enclosure. 5.
6 Disassembly 6.
6 Disassembly 1. 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 Torx screws (2,3) with the spring washers (4) from the exhaust (1). 2 1 3,4 4. Take off the exhaust (1), seal (5) with guard (6). 5. To disassemble the clutch (12) and clutch drum (9), you must block the piston. To do this, slide the piston stop wedge (0117571) into the exhaust port of the cylinder (x).
6 Disassembly 6. Loosen the clutch (12) with installation wrench (0117574) and a 19 mm ring wrench (x). Note: Left-hand thread! x 0117574 7. You can remove the tension springs (16) of the clutch (12) by using needle-nose pliers (x). 16 x 8. Take out the guide disc (11). 9. Press out the needle sleeve (10). 10. Remove the snap ring (8), take out the disc (17) and stopping ring (18).
6 Disassembly 32 Clutch
6 Disassembly 6.
6 Disassembly 1. Unscrew the screws (2). 2. Take off the starter housing (3). 3. Unscrew the screws (11) and carefully separate the air horn (6) from the starter housing (3). Note: Always proceed in the order (A - B - C - D). B 6 A D C 4. Remove any leftover old rope (13). If needed, release tension on the rope drum. 5. Take off the V-belt (10) and pull off the rope drum (5). Unscrew the Torx tapping screw (12).
6 Disassembly 6. The replacement return spring is delivered already under tension in the housing (z). CAUTION The spring can jump out. A released spring can be reinserted; see Chapter 8.7 "Assembling the recoil starter." 7. To change the starter ratchets (7), knock out the bolt (9) with a mandrel (x).
6 Disassembly 36 Recoil starter
6 Disassembly 6.
6 Disassembly 1. Open the bayonet cap (1) and take off the filter cover (2) with the prefilter (3). 2. Remove the seal rings (4,11). 4 11 3. Detach the spark plug terminal cap (6). 6 4. Remove the lower part of the plug (5). 5. Unscrew the Torx screws (10) and take off the hood (7). 6. Take off the air filter cartridge (8). 7. Remove the internal filter (9) from the intake manifold (x).
6 Disassembly 6.
6 Disassembly 1. Take the ignition cable and short circuit cable (10,1) out of the guides (x) of the hood (2). 2 x 10 1 2. Pull off the spark plug terminal cap (6) from the spark plug (7). 3. Hold the spring (8) of the spark-plug connector (6) with needle-nose pliers and slide the rubber cap to the rear over the ignition cable (10). 8 Note: 4. Apply a small amount of grease to the ignition cable (10) to make it easier to detach and attach the spark plug connector (6).
6 Disassembly 5. Unscrew the screws (3,5) and remove the hood (2). 6. The screw (5) also functions as the fastener for the ground cable. 7. Unscrew the Torx screws (11) from the magneto igniter (12), disconnect the ignition cable (10). 8. Release the short circuit cable (1) from the plug connection. 9. Release the hose clamp (14) from the suction hose. 10 11 14 10. Pull off the suction hose (15) from the cylinder (13).
6 Disassembly 11. Lift the intake manifold (16) from the tank enclosure by pressing the lever (x). x x 12. Lift the intake manifold (16) with carburetor (17) and choke shaft (18) on the cylinder side and take it out of the tank enclosure.
6 Disassembly 13. Pull the short circuit cable (1) out of the seat in the choke shaft (18). 14. Release the ground cable (4) from the plug connection of the contact spring (9). 4 9 1 18 15. Block the piston with the piston stop wedge (0117571). 16. Unscrew the nut (21) and take off the disc (20). 17. Pull off the magneto flywheel (19) with the puller (0068900). CAUTION To prevent damage to the crankshaft, always use the protection cap that belongs to the puller.
6 Disassembly 44 Ignition system module/intake manifold
6 Disassembly 6.
6 Disassembly 1. 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 opening with needle-nose pliers. 6 x 2. Press the two cylinder bolts (1) out of the handle shell (5). 3. The throttle lever (4), spring (3), throttle lever lock (2), and the gasoline locking pin (11) can now be replaced. 4. Pull the suction hose (10) out of the tank and remove the suction head (7). 5. Screw off the fuel cap (9) with seal (8).
6 Disassembly 6.
6 Disassembly 1. Unscrew the screws (16) from the cylinder (2). 2. Pull the cylinder (2) with cylinder base gasket (6) off of the crankcase halves (9,13) and piston (3). 16 3. Take out the wire snap ring (5) from the ring groove in the piston (3) using needle-nose pliers (x). 4. Press out the piston pin (4) and take off the piston. 5 x 5. Press the needle cage (7) out of the connecting rod of the crankshaft (10).
6 Disassembly 6. Unscrew the decompression valve (1) and check the valve seat as well as the bore in the cylinder (2) for dirt. 7. Replace the dirty decompression valve (1). Carefully clean the bore. 1 8. Remove the woodruff key (11). 9. Unscrew the 4 screws (15) from the crankcase half (13). Note: 10. A slip fit is located between the crankshaft (10) and the ball bearing (8) on the magnet side (MS). For this reason, always remove the "MS" first.
6 Disassembly 50 Cylinder/Crankshaft
6 Disassembly 6.
6 Disassembly 1. Unscrew the Torx screw (1) from the crankcase half (MS) and remove the disc (2). 2. Press the axle (4) out of the vibration dampers (3). 3. Pry out the vibration dampers (3) using a screwdriver. 3,4 2 1 4 3 4. Remove the 2 vibration dampers (3) from the crankcase half (CS) the same way as for the crankcase half (MS). 5. Remove the Torx screw (6) and cup attachment (5) from the crankcase half (CS). 6.
6 Disassembly 6.
6 Disassembly 1. Unscrew the screw (1) and remove the thrust washer (2). 2 1 2. Block the V-belt pulley (15) by inserting a mandrel into the bore (x). 3. Unscrew the hexagonal bolt (1) and take off the V-belt pulley (15) with shim ring (16). 15 1 x 4. To remove the second thrust washer (2), you must remove the axle (3) and distance bushing (4).
6 Disassembly 5. Unscrew the screws (17) with springs (18) from the thrust collar (5). 6. Take off the entire protective hood (8) with the parts 5,6,7,11,12. 7. Unscrew the Torx screws (10) and take off the handle (9). 17,18 8. Press the stop pin (21) and the screws (20) out of the cutting attachment (19). 21 20 19 9. Heat the cutting attachment (19). 10. Press out the ball bearing (14) and distance bushing (4). 11.
6 Disassembly 56 Protective hood/V-belt pulley
7 Disassembly/Inspection 7 Disassembly/Inspection 7.
7 Disassembly/Inspection 1. To disassemble the control side, unscrew the screws (10), carefully take off the cover (9), control diaphragm (8), seal (7) from the needle valve set (6). 2. After the control diaphragm (8) has been removed, it must lie flat. The rounded edge on the reinforcement plate (x) must be flat. Always replace the control diaphragm (8) if it is defective. 7 x 8 3. Unscrew the screw (11) and take off the needle valve set (6). 4.
Carburetor Inspections 7 Disassembly/Inspection 8. For cleaning purposes, you can take out the carburetor fuel screen (5) out of the carburetor body by carefully using a pointed object. 9. After you clean the carburetor fuel screen (5), insert it with a pin. 5 10. To test the carburetor while installed, take the fuel line out of the tank. Pull off the suction head. Set the pressure gauge (0079264) onto the reducing socket. 11. Apply 0.5 bar of pressure to the carburetor.
7 Disassembly/Inspection 60 Carburetor/Inspection
8 Assembly 8 Assembly 8.
8 Assembly 1. Attach the outer retaining clip (13). 2. Heat the cutting attachment (19) to approx. 100 °C (use industrial hot air gun). 3. Press the ball bearing (14) up against the retaining clip (13). 4. Insert the second retaining clip (13) and spacer bushing (4). 5. Also press the second ball bearing (14) up against the retaining clip (13). 19 13 14 13 4 6. Apply bonding compound to the fluted area (x) on the screws (20). 7. Insert the screws (20) and stop pin (21). 8.
8 Assembly 9. Set the inner thrust washer (2) and the distance bushing (4) onto the axle (3). 10. Insert the axle (3) into the cutting attachment (19) that is premounted to the hood. 11. Attach the shim ring (16) onto the axle (3). 12. Hold the V-belt pulley (15) against it, block it by inserting a mandrel through the bore (x) and screw it on with the hexagonal bolt (1) (torque wrench setting 25 + 5.0 Nm). 13. Screw on the handle (9) with the Torx screw (10).
8 Assembly 64 Protective hood/V-belt pulley
8 Assembly 8.
8 Assembly Note: Apply grease to the vibration dampers (3) before you install them. MS crankcase: 1. Press the axle (4) with the collar inward into the vibration damper (3). 2. Fasten with disc (2) and Torx screw (1). 3,4 2 1 CS crankcase: 3. Insert the vibration damper (3) into the crankcase at the rear. 4. Press the axle (4) with the collar inward into the vibration damper (3) and fasten it with the disc (2) and Torx screw (1) to the enclosure (torque wrench setting 6 ± 0.5 Nm). 5.
8 Assembly 8.
8 Assembly Note: The exposed side of the ball bearing (8) faces the crankshaft. Apply Omnifit 100M to the ball bearings on the outer ring before you insert them in the crankcase (CS, MS). 1. Press the ball bearing (8) onto the crankshaft (10). 2. Heat the crankcase half (9) to approx. 100 - 120 °C (use industrial hot air gun). 3. Insert the crankshaft (10) with ball bearing (8) in the crankcase half (9). 9 a 8 4. Heat the crankcase half (13) to approx.
8 Assembly 6. Set the crankcase halves (9,13) together and screw them together with the Torx screws (15). Tighten the screws crosswise (torque wrench setting 10 Nm). . 15 15 7. Press the rotary shaft seals (14) into the crankcase halves (CS, MS). 8. Insert the woodruff key (11) in the crankshaft (10). 9. Insert the needle cage (7) in the connecting rod of the crankshaft (10). 10. Fit in the cylinder base gasket (6) precisely. 11.
8 Assembly 13. Place the piston support from the set of piston rings (0117575) onto the crankcase and set the piston (3) on top. 14. Press the piston ring (17) together with the clamp set. 15. Slide the cylinder (2) on the piston (3). At the same time, move the strap (x) downward or remove it afterward. x 16. Fasten the cylinder (2) with the Torx screws (16) (torque wrench setting 14 + 1.0 Nm). 17. Insert the decompression valve (1).
8 Assembly 8.
8 Assembly 1. 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 (4), spring (3), throttle lever lock (2), and the gasoline locking pin (11) and insert them into the handle shell. 4. Fasten with the parallel pins (1). 5. Using a mandrel (x), press the vent valve (6) into the tank (5) far enough so that the white plastic tip (y) protrudes about 2 - 3 mm. 6. Screw the tank (5) together with the premounted crankcase.
8 Assembly 8.
8 Assembly 1. Clean the cone (x) of the crankshaft and magneto flywheel. x 2. Set the magneto flywheel (19) onto the crankshaft. 3. Screw the hexagonal nut (21) with the spring washer (20) onto the crankshaft (torque wrench setting 30 - 5 Nm). 4. Connect the ignition cable (10) and short circuit cable (1). 5. Set the setting gauge (y) between the magneto igniter (12) and magneto flywheel (19). y 12 19 6.
8 Assembly 10. Screw the carburetor (17) onto the intake manifold (16) (torque wrench setting 1.5 ± 0.5 Nm). 11. Connect the suction hose (15) to the intake manifold (16). 12. Slide the hose clamp (14) over the suction hose (15). 13. Place the intake manifold (16) into the tank enclosure. 14. Attach the suction hose (15) onto the cylinder (13) and fasten with the hose clamp (14). 15. Screw the spark plug into the cylinder (13) and tighten it. 16.
8 Assembly 19. Press in the hook (w) of the spring (8) into the center of the ignition cable (10) from the top. 20. Pull the rubber cap over the spring (8). w 8 Note: 21. An incorrectly mounted spring (8) can cause weak ignition sparks or lead to complete failure. Plug the spark plug terminal caps (6) onto the spark plugs (7).
8 Assembly 8.
8 Assembly 1. Lay the internal filter (9) into the intake manifold (x). x 9 2. Set the air filter cartridge (8) onto the internal filter (9). 3. Screw the hood (7) onto the intake manifold (x) with the Torx screws (10). 4. Insert the seal rings (4,11). 4 11 5. Insert the lower part of the plug (5). 6. Attach the spark plug cap (6). 6 7. Press the prefilter (3) into the filter cover (2). Note: 8. Align the prefilter (3) with the filter cover holder.
8 Assembly 8.
8 Assembly 1. 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 between the starter ratchet (7) and bolt (9). Attach the springs. 3. Apply a light coat of multipurpose grease to the new return spring (4) before you install it in the starter housing (3). Insert the return spring (4) and press gently against it so that the tabs (y) snap into the holders. Do not grease the rope drum (5) and journals (z)! 4.
8 Assembly 7. Pass the rope through the recess (x) on the rope drum (5) and, together with the rope, turn the rope drum (5) twice in the direction of the arrow. 8. Hold the rope drum (5) firmly with your left hand, untwist the rope (13) with your right hand, pull the rope (13) taut and hold it tightly. 9. Carefully release the rope drum (5). The spring tension will cause the rope drum (5) to wind up the rope (13). 5 13 x 10. Repeat the procedure three times.
8 Assembly 82 Recoil starter
8 Assembly 8.
8 Assembly 1. 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 disc (17). 3. Grease the needle sleeve (10) with multipurpose grease. 4. Press the needle sleeve (10) into the clutch drum (9). 17 10 5. Press the guide disc (11) into the receptacle of the clutch drum (9). 6. Block the piston with piston stop wedge (0117571) in the exhaust port of the cylinder (x). x 0117571 7.
8 Assembly 9. Remove the stop wedge. 10. Attach the guard (6) directly on the cylinder, then screw on the seal (5) and muffler (1) with Torx screw (2), screw (3) with disc (4) and tighten them (torque wrench setting 8 Nm). 11. Attach the V-belt (13). 12. Screw the cover (14) onto the crankcase half (7) with the Torx screws (15). 13. Tighten the V-belt, see Chapter 10.4.
8 Assembly 86 Clutch
8 Assembly 8.
8 Assembly 1. Screw on the bushing (12) and the pulleys (13) to the foot (16) using the Torx screw (14). 2. Fasten the handle (1) and foot (10 or 16) with Torx screw (11). 3. Fasten the side brace (7) with Torx screw (8,9). 4. Tighten the Torx screws (11,8,9) (torque wrench setting 7 ± 0.5 Nm). 7 8 1 9 5. After you mount the cutting attachment (see 8.1), attach it to the unit and tighten the nuts (5) by hand. 6.
9 Malfunction 9 Malfunction Malfunction System Observation Cause Cutting disc does not start Clutch Engine is running Clutch is damaged Cutting disc rotates when engine is idling Carburetor, clutch Cutting disc rotates Idle setting incorrect, clutch is blocked Engine will not start or is hard to start Ignition system There is an ignition spark Malfunction in the fuel supply, compression system, mechanical fault No ignition spark STOP switch was actuated, fault or short-circuit in the cable
9 Malfunction 90
10 Maintenance 10 Maintenance 10.1 Maintenance schedule Users of cut-off saws are only permitted to carry out the maintenance and care procedures outlined in this repair manual. All other procedures may only be carried out by a Wacker service station. Maintenance interval Component Maintenance work Entire cut-off saw Clean the outside and check for damage.
10 Maintenance Maintenance interval Component Maintenance work Entire cut-off saw Clean the outside and check for damage.
10 Maintenance 10.2 Cleaning the protective hood • • • With time, material deposits will form on the inside of the protective hood (particularly when wet cutting). Under certain circumstances, these deposits can hinder the free rotation of the cutting disc. Detach the cutting disc and thrust washer and remove the material deposits on the inside with a wood strip or similar tool. Wipe off the shaft and all disassembled parts with a clean cloth.
10 Maintenance 10.3 Replacing the V-belt • • • • Loosen the nuts (3). Loosen the tension screw (1) (counterclockwise) until you see the screw end (2) in the gap. Unscrew the nuts (3) and remove the cap (4). Unscrews the screws (5) and (7) and take off the side brace (6). Note: • • • Screw (5) is longer than screws (7). Observe the installation position during assembly! Loosen the screws (8) and take off the crankcase cover (9). Remove the old V-belt (10) or any leftover V-belt material.
10 Maintenance 10.4 Tightening the V-belt Note: To obtain the maximum cutting performance at the lowest fuel consumption, it is absolutely necessary to tighten the V-belt precisely. An incorrectly tightened V-belt leads to premature wearing of the V-belt and V-belt pulley or to damage on the clutch bearing. Do not retighten the V-belt until after one hour of operation! Note: To tighten the V-belt and to check the tension, you must loosen both mounting nuts (11).
10 Maintenance 10.5 Carburetor setting 1. To make the basic setting, carefully turn the idle jet "L" inward as far as it goes. Screw the "L" jet outward according to the following table. 2. To make the basic setting, carefully turn the idle jet "H" inward as far as it goes. Then screw the "H" jet outward according to the following table. 3. Use the stop screw "S" for the choke to set the engine's idle speed. 4. The cutting disc rotates: Screw the "S" screw outward. 5.
10 Maintenance BTS 930 L3 BTS 935 L3 BTS 1030 L3 BTS 1035 L3 H adjusting screw 1 1/4th of a revolution outward 1 1/4th of a revolution outward L adjusting screw 1 1/4th of a revolution outward 1 1/4th of a revolution outward S adjusting screw Cutting disc must not rotate Cutting disc must not rotate Setting Due to the exhaust emission standards currently in effect, the L and H adjusting screws of the unit are not accessible from the outside.
10 Maintenance 10.6 Cleaning/Changing the air filter • • • • Turn the cover lock (11) to the "unlocked" position and carefully remove the filter cover (12). Two sealing rings (15) are located between the filter cover (12) and the hood (14). Loosen the screws (13) and take off the hood (14). Clean the sealing rings (15) using a small brush and check for signs of damage.
10 Maintenance • • • Take the prefilter (17) out of the filter cover. Pull the air filter cartridge (18) out of the hood. Take the internal filter (16) off the suction head. Note: • Protect the carburetor to prevent dirt from falling into it! Put the multifunction switch in the "Choke" position or cover the carburetor with a clean cloth. 1 2 3 1. Prefilter (foam) and internal filter.
10 Maintenance 2. Air filter cartridge (paper cartridge) • • • The air filter cartridge (2) filters the intake air through fine paper filter lamella. Thus never wash out the cartridge. Clean the air filter cartridge (2) once a week. Expand the lamella of the air filter cartridge (2) slightly, lay it on a clean pad and carefully tap against it. Replace the air filter cartridge (2) after every 100 hours of operation.
10 Maintenance 10.7 Replacing the spark plug • The spark plug must be replaced if the ceramic insulator is damaged, or if the spark plug electrodes are severely burned, very dirty or oily. DANGER Do not touch the spark plug or spark plug connector while the engine is running (high voltage). Carry out maintenance work only when the engine is off. Hot engine can cause burns. Wear protective gloves! Note: • • Use only BOSCH WSR 6F, CHAMPION RCJ-6Y or NGK BPMR 7A spark plugs as replacements.
10 Maintenance Spark plug picture Appearance Normal view Deposits Overheating Carbon deposits Cause Proper spark plug Good combustion Poor quality, material wear Incorrect thermal value Incorrect spark plug Incorrect thermal value 1. Ignition test • Insert the combination wrench (3) between the hood and cylinder, as shown in the figure. CAUTION Do not insert the wrench into the spark plug hole; just make contact with the cylinder (otherwise you may damage the engine).
10 Maintenance 10.8 Replacing the suction head • • • • The felt filter (13) of the suction head can become clogged during operation. To ensure an unrestricted flow of fuel to the carburetor, the suction head should be replaced about every 3 months. Unscrew the fuel tank cap (12), pull the retainer out of the tank opening. Empty the tank. To change it, pull the suction head through the tank cap opening using a wire hook. DANGER Avoid skin and eye contact with mineral products! 10.
10 Maintenance 10.10 Miscellaneous 1. Cutting attachment in the center/outer position Note: 2. The cutting attachment is mounted at the factory for operation in the center position (1). The cutting attachment can be mounted in the outer position (2) to maneuver around obstacles that are very close to the cutting line (for curbs, or brick walls). Use the outer position for guiding the cut-off saw by hand only for the work at hand. Afterwards, mount the cutting attachment back to the center position.
10 Maintenance • Pry out the stop pin (7) with the combination wrench (8) far enough, as shown in the figure, so that you are able to turn the protective hood (10). Note: • • • • Once the stop pin (7, Fig. page 104) has been pulled out, the rotary stop (7) is deactivated. This makes it possible to turn the protective hood (10) beyond the rotary stop (7). Unscrew the handle (9) and turn the protective hood (10), as shown in the figure. Detach the V-belt (11) and remove the cutting attachment.
10 Maintenance • • • • Place the cover (15) on top. Screw on the nuts (16) and tighten by hand. Tighten the V-belt, see Chapter "Tightening the V-belt/Checking the tension." Tighten the nuts (16) securely with the combination wrench.
11 Torque values 11 Torque values Type ft lb Nm ft lb Nm ft lb Nm inch Met. inch Met. M3 *11 1.2 *14 1.6 *19 2.1 7/32 5.5 - 2.5 M4 *26 2.9 *36 4.1 *43 4.9 9/32 7 - 3 M5 *53 6.0 6 8.
11 Torque values 108
