Summary of Contents for Wacker Neuson BTS 930-8340
- Page 1 0118754en 0903 Cut-Off Saws BTS 930-8340 BTS 935-8341 BTS 1030-8339 BTS 1035-7975 REPAIR MANUAL...
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Page 3: Table Of Contents
BTS Repair Table of Contents Technical Data BTS 930 / BTS 935 / BTS 1030 / BTS 1035 ........5 Special Tools Clutch Dismantling the clutch/drum ..............7 Mounting muffler and heat plate ............8 Repairing the clutch ................8 Mounting the clutch/drum .............. - Page 4 Table of Contents BTS Repair Hood System / Air Filter / Winter Operation Air Filter ....................22 Winter Operation .................23 Front Handle / Vibration Absorbers Removing and replacing the bracket handle ........24 Replacing the vibration absorbers ............24 Fuel Tank / Fuel Filter Removing/inserting the ventilation valve ..........25 Replacing the throttle lever mechanism ..........25 Replacing the fuel pipe ................26...
- Page 5 BTS Repair Table of Contents 12.8 Removing / mounting the cutting device bearings ......33 12.9 Adjusting the cutter guard holding attachment ........34 12.10 Tensioning the V-belt ................. 34 13. Torques 13.1 BTS 930 / BTS 935 / BTS 1030 / BTS 1035 ........35 wc_br0118754enTOC.fm...
- Page 6 Table of Contents BTS Repair wc_br0118754enTOC.fm...
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Page 7: Technical Data
BTS Repair Technical Data Technical Data BTS 930 / BTS 935 / BTS 1030 / BTS 1035 Item No. BTS 930 BTS 935 BTS 1030 BTS 1035 0008340 0008341 0008339 0007975 Displacement cm³ (in³) Bore mm (in.) 47 (1.8) 50 (2.0) Stroke mm (in.) 37 (1.5) -
Page 8: Special Tools
Special Tools BTS Repair Special Tools wc_gr001381 Ref. Part Number Description 0068900 Puller for flywheel 0117570 Puller for oil seals 0117573 Puller for ball bearing counter support 0117569 Puller for ball bearing inside puller 0117575 Set of piston ring tenson belt 0117571 Piston stop wedge 0117574... -
Page 9: Clutch
BTS Repair Clutch Clutch Dismantling the clutch/drum See Graphic: wc_gr001384 and wc_gr001385 3.1.1 To dismantle the clutch and drum, remove the cutting device (1), strut (2) and V-belt cover (3). 3.1.2 To remove the cutting device, loosen the fixing screws (4). Remove screw (5) to the point where the end of the screw projects from the cover (arrow). -
Page 10: Mounting Muffler And Heat Plate
Clutch BTS Repair Mounting muffler and heat plate See Graphic: wc_gr001386 When mounting the muffler (10) ensure that the heat plate (12) is installed correctly. Note: The heat plate goes directly onto the cylinder, then the gasket (13) and muffler. 1 1 2 1 1 0 1 1 3... -
Page 11: Mounting The Clutch/Drum
BTS Repair Clutch Mounting the clutch/drum See Graphic: wc_gr001387 3.4.1 Before installing the clutch drum, the needle bearing that is pressed in must be greased. (Alvania #2) 3.4.2 When mounting the drum and the clutch, be careful to mount the washers in the right order. -
Page 12: Ignition System
Ignition System BTS Repair Ignition System Checking the spark plug See Graphic: wc_gr001388 4.1.1 Remove filter hood. 4.1.2 Pull spark plug socket (1) off the spark plug and remove spark plug (2). 4.1.3 Connect spark plug (2) with plug socket and hold to ground (3). Pull out starter cable. -
Page 13: Replacing The Plug Connector
BTS Repair Ignition System Replacing the plug connector See Graphic: wc_gr001389 Hold the plug connector spring using pointed pliers and push the rubber cap backwards over the ignition cable. Note: Grease the ignition cable slightly beforehand. wc_gr001389 wc_tx000299gb.fm... -
Page 14: Removing/Assembling The Ignition / Short Circuit Cable
Ignition System BTS Repair Removing/assembling the ignition / short circuit cable See Graphic: wc_gr001390, wc_g001391, wc_gr001392 and wc_gr001393 Removing 4.3.1 Unscrew the starter device that is fixed with 4 screws (a). 4.3.2 Unscrew filter hood. 4.3.3 Remove ignition and short circuit cable from the guide (1) of the hood. 4.3.4 Remove hood - to do this, unscrew the 3 screws (2). - Page 15 BTS Repair Ignition System wc_gr001392 Assembling 4.3.1 When mounting the short circuit cable, make sure that the connection between the connector lug of the short circuit cable and the contact spring is in order (a). 4.3.2 Twist ignition cable into the ignition armature. Note: To prevent moisture leaking in, fill protective cap (4) with silicone before replacing.
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Page 16: Removing/Checking/Mounting The Ignition Armature
Ignition System BTS Repair Removing/checking/mounting the ignition armature See Graphic: wc_gr001394 Removing 4.4.1 Unscrew starting device. 4.4.2 Remove the two screws (1) of the ignition armature. Clip off ignition and short circuit cable. Checking 4.4.1 In the event of a fault, first check the ignition ground connection. To do this, loosen and then tighten the screws (1) a few times, then check ignition once again. -
Page 17: Removing/Mounting The Flywheel
BTS Repair Ignition System Removing/mounting the flywheel See Graphic: wc_gr001395 Removing 4.5.1 Block the piston using the piston stop wedge. 4.5.2 Unscrew bolt (2) and remove washer (3). 4.5.3 Remove flywheel with pulling device 0037576 (a). CAUTION: To avoid damage to the crankshaft, always use the protective cap included with the pulling device. -
Page 18: Starting System
Starting System BTS Repair Starting System Removing/mounting the starter / return spring See Graphic: wc_gr001396 Removing the starter 5.1.1 Remove air duct (1). 5.1.2 Relieve the tension on the return spring by pulling out the starter cable (2) slightly. 5.1.3 Hold cable drum and remove cable from rope drum. -
Page 19: Pretensioning/Checking The Return Spring
BTS Repair Starting System Pretensioning/checking the return spring See Graphic: wc_gr001367 Pretensioning the return spring Wrap the starter cable as far as possible around the drum. Hold cable tight and turn the drum with the cable 2-3 times to pretension (a). Checking the return spring When the starter cable is fully extended, the rope drum must still turn at least half a turn (b). -
Page 20: Carburetor
Carburetor BTS Repair Carburetor Setting the carburetor See Graphic: wc_gr001398 Set Idling Nozzle “L” at 1 3/8 (-1/16) turn For the basic setting, turn in the idling nozzle “L” carefully as far as it will go. Then back off “L” nozzle 1 3/8 turn. For fine tuning, the “L”... -
Page 21: Removing The Carburetor And Intake Hose
BTS Repair Carburetor Removing the carburetor and intake hose See Graphic: wc_gr001399 Removing the carburetor 6.2.1 Remove intake elbow with carburetor. 6.2.2 Remove choke shaft (1), choke rod (2) and throttle control rod (3). Unscrew the two fixing screws (4). 6.2.3 Remove the carburetor from the intake elbow. -
Page 22: Carburetor - Dismantling/Testing The Control Side
Carburetor BTS Repair Carburetor - dismantling/testing the control side See Graphic: wc_gr001400 Dismantling the control side 6.3.1 Unscrew cover (1). Carefully remove the seal (2) and diaphragm (3) from the control lever (4). 6.3.2 Remove control lever, spring (5) and inlet needle (6) from the carburetor. -
Page 23: Carburetor - Dismantling/Testing The Pump Side
BTS Repair Carburetor Carburetor - dismantling/testing the pump side See Graphic: wc_gr001401 Dismantling the pump side Unscrew cover (8). Remove seal (9) and diaphragm (10) from the carburetor. Testing the pump membrane The two valve flaps (arrow) must rest flat on the body of the carburetor. Damaged diaphragms must be replaced immediately, as starting and running problems may otherwise occur. -
Page 24: Hood System / Air Filter / Winter Operation
Hood System / Air Filter / Winter Operation BTS Repair Hood System / Air Filter / Winter Operation Air Filter See Graphic: wc_gr001402 Only well-maintained filters will guarantee efficient engine performance and a long working life. Damaged or worn filters must therefore be replaced. -
Page 25: Winter Operation
BTS Repair Hood System / Air Filter / Winter wc_gr001403 Winter Operation See Graphic: wc_gr001403 Temperatures below zero may cause the filter/ carburetor to freeze. Remove summer-winter insert from summer mode (6) and insert in winter mode (7) as shown. Return to summer mode when temperature is above 32°F (0°C). -
Page 26: Front Handle / Vibration Absorbers
Front Handle / Vibration Absorbers BTS Repair Front Handle / Vibration Absorbers Removing and replacing the bracket handle See Graphic: wc_gr001404 To dismantle the front handle, the strut (1) with 3 screws and the foot (2) with 2 screws must be unscrewed. wc_gr001404 Replacing the vibration absorbers See Graphic: wc_gr001405... -
Page 27: Fuel Tank / Fuel Filter
BTS Repair Fuel Tank / Fuel Filter Fuel Tank / Fuel Filter Removing/inserting the ventilation valve See Graphic: wc_gr001406 Removing Push the ventilation valve with a pin into the tank (arrow) and remove with pointed pliers through the filler opening (a). Inserting Press the new ventilation valve with a pin into the housing until the white sinter plastic projects about 2–3 mm beyond the tank (b). -
Page 28: Replacing The Fuel Pipe
Fuel Tank / Fuel Filter BTS Repair Replacing the fuel pipe See Graphic: wc_gr001407 Unscrew tank cap, remove suction head (7) from tank and pull off the suction pipe (8). Pull suction pipe upwards out of the tank. wc_gr001407 Testing the fuel filter See Graphic: wc_gr001407 Dirty felt filters or filters which have become hardened/blocked with fuel will lead to leaning of the fuel/air mix and will damage the engine... -
Page 29: Cylinder / Piston / Decompression Valve
BTS Repair Cylinder / Piston / Decompression Valve 10. Cylinder / Piston / Decompression Valve 10.1 Dismantling/mounting the cylinder / piston See Graphic: wc_gr001408 and wc_gr001409 Dismantling the cylinder 10.1.1 To dismantle the cylinder, unscrew the 4 screws (1) from the cylinder foot. -
Page 30: Testing The Decompression Valve
Cylinder / Piston / Decompression Valve BTS Repair wc_gr001409 10.2 Testing the decompression valve See Graphic: wc_gr001409 Unscrew valve and check valve seating (a) and the hole in the cylinder for dirt. Replace valve if dirty. Clean hole carefully. wc_tx000305gb.fm... -
Page 31: Crankcase / Crankshaft
BTS Repair Crankcase / Crankshaft 11. Crankcase / Crankshaft 11.1 Crankcase / crankshaft See Graphic: wc_gr001410 and wc_gr001411 Complete crankcase The complete crankcase is divided into the crankcase magnet side (2) “MS”, and the crankcase clutch side (1) “KS”. Removing the crankcase “MS” To dismantle the magnet side (MS), unscrew the 4 fixing screws (3) and the left lower screw (4). -
Page 32: Cutting Attachment
Cutting Attachment BTS Repair 12. Cutting Attachment 12.1 Replacing the pressure disc See Graphic: wc_gr001412 12.1.1 Undo screw (1) and remove pressure disc. Note: With the 25.4 mm (1") axle, the inner flange is located behind the recess of the axle (2). 12.1.2 Remove axle and flange together. -
Page 33: Replacing The Drive Axle
BTS Repair Cutting Attachment 12.3 Replacing the drive axle See Graphic: wc_gr001413 To remove the axle (7), the pressure disk (8) and the V-belt pulley must be dismantled. Note: When mounting the inner flange disk, make sure that the spacer sleeve (9) 0108151 is mounted. -
Page 34: Replacing The Guard Stop
Cutting Attachment BTS Repair 12.6 Replacing the guard stop See Graphic: wc_gr001414 Knock the shaft (1) with a pin out of the handle (2). To assemble, push the new handle onto the shaft until the shaft is flush with the outside edge of the handle. wc_gr001414 12.7 Replacing the fixing screw See Graphic: wc_gr001414... -
Page 35: Removing / Mounting The Cutting Device Bearings
BTS Repair Cutting Attachment 12.8 Removing / mounting the cutting device bearings See Graphic: wc_gr001415 Removing 12.8.1 Warm housing, remove ball bearings, spacer sleeve and snap rings from the housing. Mounting 12.8.1 Heat housing up to approx. 212°F (100°C). 12.8.2 Mount external snap ring (4). 12.8.3 Push ball bearing (5) up against the ring. -
Page 36: Adjusting The Cutter Guard Holding Attachment
Cutting Attachment BTS Repair 12.9 Adjusting the cutter guard holding attachment See Graphic: wc_gr001416 If the guard is subjected to high stresses, the holding attachment and the guard may no longer be aligned (arrows). For correction, loosen screws (8) and adjust holding attachment. wc_gr001416 12.10 Tensioning the V-belt See Graphic: wc_gr001416... -
Page 37: Torques
BTS Repair Torques 13. Torques 13.1 BTS 930 / BTS 935 / BTS 1030 / BTS 1035 Assembly set Nm (ft.lbs.) Muffler 10 + 1 (7) ** Crankcase 10 + 1 (7) ** Cylinder 14 + 1 (10) ** Ignition coil 6 + 1 (53 in.lbs.) ** Front handle 7 ±... - Page 38 Torques BTS Repair wc_tx000327gb.fm...
- Page 39 Threadlockers and Sealants Threadlockers and Sealants Threadlocking adhesives and sealants are specified throughout this manual by a notation of “S” plus a number (S#) and should be used where indicated. Threadlocking compounds normally break down at temperatures above 175°C (350°F). If a screw or bolt is hard to remove, heat it using a small propane torch to break down the sealant.
- Page 40 Threadlockers and Sealants TYPE PART NO. - ( ) = Europe COLOR USAGE SIZE Loctite Primer T Aerosol Fast curing primer for threadlocking, retaining and 2006124 - Hernon Primer 10 Spray sealing compounds. Must be used with stainless 6 oz. Omnifit VC Activator steel hardware.
- Page 41 Torque Values Torque Values Metric Fasteners (DIN) TORQUE VALUES (Based on Bolt Size and Hardness) WRENCH SIZE 10.9 12.9 Size ft.lb. ft.lb. ft.lb. Inch Metric Inch Metric 7/32 9/32 5/16 11/16 15/16 1-1/16 1-1/4 1 ft.lb. = 1.357 Nm. * = in.lb. 1 Inch = 25.4 mm...
- Page 42 Torque Values Inch Fasteners (SAE) Size ft.lb. ft.lb. ft.lb. Inch Metric Inch Metric No.4 3/32 No.6 5/16 7/64 No.8 11/32 9/64 No.10 5/32 7/16 3/32 5/16 9/16 5/16 7/16 9/16 13/16 15/16 1-1/8 1 ft.lb. = 1.357 Nm. * = in.lb. 1 Inch = 25.4 mm...
- Page 44 Wacker Construction Equipment AG · Preußenstraße 41 · D-80809 München · Tel.: +49-(0)89-354 02 - 0 · Fax: +49 - (0)89-354 02-390 Wacker Corporation · P.O. Box 9007 · Menomonee Falls, WI 53052-9007 · Tel. : +1-(1)(262) 255-0500 · Fax: +1-(1)(262) 255-0550 · Tel. : (800) 770-0957 Wacker Asia Pacific Operations ·...